the natural performance advantage - castrol · cutting the compromise a reliance on the performance...
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Best on test neat cutting FLuiD The NaTural PerformaNce advaNTage
eXecutiVe summaRYthe metaLWoRKing sectoR’s neeD FoR high PeRFoRmance neat FLuiDs has Long ResuLteD in an inDustRY-WiDe gRaVitation toWaRDs mineRaL-BaseD PRoDucts.
Flashpoint problems and environmental
responsibility concerns have spurred over
20 years of research and development
into alternative, plant-based chemistries.
But in the absence of formulas that
can deliver comparable performance to
mineral-based fl uids and help enhance
the working environment– at an
attainable cost – OEMs and operators
have found it diffi cult to justify switching
from the status quo. Up to now, the
challenge has always been to produce a
long life plant-based product.
Innovation has come a long way from
the traditional, darker colour, stronger
smelling vegetable fl uids that soon turned
rancid. A gradual move to synthetic
esters has brought us closer to a category
capable of wider market penetration –
though even second and third generation
plant-based fl uids have struggled with
lifespan challenges surrounding oxidation
stability.
With the next generation of plant-
based fl uids now coming to the fore, is
the natural order of things about to be
disrupted?
Proving the problems with premature
breakdown have been overcome and
demonstrating value-add from a total
cost of ownership (TCO) perspective are
key to convincing a sceptical buyer of the
natural performance advantage that can
be achieved with the latest plant-based
fl uid technologies.
This paper, which draws upon industry-
accepted, laboratory-based testing
methodologies, aims to benchmark a
range of widely available mineral-and
plant based metalworking fl uids.
The ultimate objective of this study is
to help those involved in fl uid selection
make more informed and responsible
cutting fl uid choices that impact upon
their working environments, sustainable
performance and operational viability.
cutting the comPRomise a ReLiance on the PeRFoRmance attRiButes oF tRaDitionaL mineRaL-BaseD FLuiDs has histoRicaLLY inVoLVeD ceRtain comPRomises, incLuDing unPLeasant WoRKing conDitions anD unDesiRaBLe eXteRnaL enViRonmentaL imPact.
While plant-derived products have
attempted to deliver an acceptable
alternative, metalworkers have been left
dealing with messy machinery and more
frequent changeovers due to problems
with oxidation stability and related
in-use issues. Indeed, the opportunity to
narrow the performance gap between
mineral-based fl uids at one end of the
spectrum and plant-based fl uids at the
other has proven problematic. However,
a new selection of plant-based grades
from Castrol – Performance Bio NC
fl uids – could help to cut many of the
compromises previously attributed to
so-called ‘biolubes’.
DeFining PeRFoRmance the PeRFoRmance oF a FLuiD in machining can Be BRoaDLY consiDeReD in teRms oF its aBiLitY to enhance PRoDuction.
Whether that is through supporting greater productivity, more precise working or
better quality outputs, cutting and cooling fl uids have a signifi cant impact on overall
factory performance, contributing directly and indirectly to:
Throughput
Fluids that promote faster and longer
working – either due to retained
lubricity and/or more conducive working
environments.
Consistency
Cutting fl uids that run cleaner in machines
and promote precision working to attain a
high quality and/or consistent fi nish.
Flexibility
Fluids that can be ‘performance matched’
to a variety of metalworking applications,
thereby reducing the incidence of fl uid
changeovers, tool replacements and
substitute materials.
Using in-house and industry-recognised
methodologies, the tests were conducted
under controlled conditions by Castrol’s
technical experts in collaboration with
external laboratories. The following
benchmarking tests were performed,
recorded and validated during the period
April-June 2013.
The Rotating Pressurized Vessel Oxidation Test (RPVOT)
A measure of oxidation stability. It works
by stressing the fluid in an oxidating
environment that includes heat, water, a
copper catalyst, pressurized oxygen and
agitation. The deciding factor is the length
of time the fluid can resist these stressing
conditions before the break point is
reached and the fluid degrades (oxidizes).
Flashpoint
Using the standard ‘open cup’ test
method, the lowest temperature at which
the fluid vapour forms an ignitable
mixture in the air was obtained.
testing methoDoLogies muLtiPLe tests haVe Been conDucteD on a Range oF comPaRaBLe mineRaL anD PLant BaseD FLuiDs.
Air Release
Designed to measure how quickly air
bubbles dissipate from fluids, this is an
important performance indicator as the
presence of too much air reduces cooling
and lubricating properties.
Load carrying and anti-wear tests
These tests involve rotating test pieces
and measuring a force or load (in
Newtons) under fixed test conditions.
This information is used to compare the
lubrication properties of various products.
The Tapping torque test is conducted
by cutting or forming a thread into a
pre-drilled hole. This is a test relevant to
certain machine tool applications and is a
measure of how much energy is required
to ‘tap’ a hole. Test results are normalized
and compared to a reference, and the best
result is the sample with the lowest torque.
4-ball testing is used to compare
load-carrying or anti-wear properties of
products to each other. The 4-ball wear
scar test is executed, for an extended time
under a fixed load. The subsequent wear
scar diameters on the balls are measured.
test sites anD Dates BP Italy Turin Technology Centre, Italy (April-May 2013):
Shell 4-ball Test (ASTM D2783/98), Foam Test on Neat Fluids (ASTM D892),
Flash Point (ASTM D 92), Tapping Torque Test
BfB Oil Research S.A., Belgium (May 2013):
RPVOT Oxidation Test (ASTM D2272)
BP Pangbourne Laboratories, UK (May-June 2013):
Air Release Test
Castrol
• Performance Bio NC Super Lite (8 cSt)
Plant-based fluid & synthetic
hydrocarbon blend
• Performance Bio NC Ultra Lite (16 cSt)
Plant-based fluid & synthetic
hydrocarbon blend
• Performance Bio NC Lite (35 cSt)
Plant-based fluid & synthetic
hydrocarbon blend
• Performance Bio NC Plus (40 cSt)
Plant fluid
PRoDucts anD categoRisation the FoLLoWing DescRiPtoRs WiLL Be useD thRoughout the RemainDeR oF the PaPeR.
• Variocut G 600 HC (8 cSt)
Mineral-based fluid
• Variocut G 613 HC (13 cSt)
Mineral-based fluid
They apply to a group of 10 individual fluids available on the open market from
Castrol and other well-known fluid suppliers. The specific viscosity index of each
product is provided in brackets:
For the purpose of comparing each product appropriately, please refer to the viscosity bands in the following table.
Green text and bar charts indicate a plant or plant-based product, while black text and bar charts illustrate a mineral-based fluid:
Brand A
• Plant fluid A (40 cSt)
• Plant-based fluid A (22 cSt)
Brand B
• Plant fluid B (35 cSt)
Brand C
• Mineral-based fluid C (15 cSt)
Low (5-9 cSt)
Medium-low (10-16 cSt)
Medium-high (20-30 cSt)
High (35-40 cSt)
Performance Bio NC Super Lite
Variocut G 600 HC
Performance Bio NC Ultra Lite
Variocut G 613 HC
Mineral-based fluid C
Performance Bio NC Lite
Plant-based fluid A
Performance Bio NC Plus
Plant fluid A
Plant fluid B
Overcoming the oxidation stability challenge
• Performance Bio NC Plus and NC Lite
are markedly more stable than the other
plant-based fl uids on test.
• Performance Bio NC Super Lite and NC
Ultra Lite now provide operators with
the same level of oxidation stability as
mineral-based fl uids
• Variocut G 600 HC shows the best
oxidation stability results overall.
Oxidation stability is an important attribute
from a performance standpoint because
a composition that degrades more slowly,
performs for longer. Retained lubricity
reduces wear on tools, thereby maintaining
the precision and quality of the fi nish
for longer.
Less frequent changeovers also mean
less downtime. In the past, plant-based
products have struggled to achieve the
same levels of stability as their mineral-
based counterparts. Coupled with
this, plant-based fl uids have become
synonymous with messy fl uid breakdown,
prohibiting widespread worker acceptance.
The results attributed to Performance
Bio NC Ultra Lite and Super Lite indicate
that these issues have been largely
overcome and there is now a plant-based
alternative to mineral-based fl uids in terms
of oxidative stability. The advantage of
using a high viscosity Performance Bio
NC fl uid is even more marked, according
to the oxidation data, with up to 50%
improvement over the next best,
plant-derived fl uid.
Test 1: Oxidation stability via RPVOT
Brand A: Plant fl uid (40 cSt)
Brand A: Plant-based fl uid (22 cSt)
Brand B: Plant fl uid (35 cSt)
Performance Bio NC Lite (25 cSt)
Performance Bio NC Plus (40 cSt)
Variocut G 613 HC (13 cSt)
Performance Bio NC Super Lite (8 cSt)
Performance Bio NC Ultra Lite (16 cSt)
Brand C: Mineral-based fl uid (15 cSt)
Variocut G 600 HC (8 cSt)
0 20 40 60 80 100 120 140 160 180 190 200
Oxidation Onset Time (minutes)
Higher fl ash points; lower risk
• The highest viscosity Performance Bio
fl uid (NC Plus) has the highest fl ashpoint
of the plant-based fl uids tested
• Plant-based formulations, with high
viscosities are safer, with fl ash points
surpassing 200°C
For all the performance merits of mineral-
based fl uids, relatively low fl ash points
have long presented a problem for those
specifying such lubricants. Fires can occur
in metalworking environments when
fl uid fl ow is unable to moderate the
temperature of the workpiece. These
incidents are relatively rare; so many
Test 2: Flash point
Variocut G 600 HC (8 cSt)
Variocut G 613 HC (13 cSt)
Performance Bio NC Super Lite (8 cSt)
Performance Bio NC Ultra Lite (16 cSt)
Brand C: Mineral-based fl uid (15 cSt)
Performance Bio NC Lite (25 cSt)
Brand A: Plant-based fl uid (22 cSt)
Brand A: Plant fl uid (40 cSt)
Brand B: Plant fl uid (35 cSt)
Performance Bio NC Plus (40 cSt)
0 50 100 150 200 250 300 350
Temperature (°C)
manufacturers don’t tend to see this as
an overriding concern. However, factor in
the time spent dealing with fl ammability
issues, insurance risks and employee safety,
and the impact on productivity and staff
wellbeing could be notable.
With a fl ash point of 296°C, under
laboratory conditions, it is clear the natural
choice when it comes to fl ash point safety
is Performance Bio NC Plus. However, for
an excellent combination of oxidation
stability and fl ashpoint, OEMs should
consider NC Ultra Lite, depending on
operating temperatures and application.
Faster air release delivers record results
• Performance Bio NC Plus separates
entrained air almost 20 times quicker
than a competitive plant-based product
with similar viscosity (Brand A: plant
fl uid 40 cSt)
A mixture of air and fl uid circulating
through the lubrication system often
results in impaired performance due to
reduced cooling and lubricating properties.
Mineral-based fl uids tend to offer better
results in this respect and so harnessing
comparable features from a plant-based
product represents signifi cant advances in
fl uid technology.
Performance Bio NC Plus presents
OEMs with an excellent plant-based
option for mitigating against entrained
air under operating conditions. In our
laboratory, dispersal rates for this product
outperformed all other fl uids on test.
NB: No results are available for
Performance Bio NC Super Lite.
The volatility of one of its components
meant that no data could be recorded
under the conditions of the test.
Test 3: Air release
Brand A: Plant fl uid (40 cSt)
Performance Bio NC Lite (25 cSt)
Brand C: Mineral-based fl uid (15 cSt)
Performance Bio NC Ultra Lite (16 cSt)
Brand A: Plant-based fl uid (22 cSt)
Variocut G 613 HC (13 cSt)
Brand B: Plant fl uid (35 cSt)
Variocut G 600 HC (8 cSt)
Performance Bio NC Plus (40 cSt)
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
Time (minutes)
Extended tool life enhances product fi nish
• Higher viscosity fl uids performed best
on test, with Performance Bio NC Plus
delivering the most impressive results
• Mineral-based blends, in general, gave
higher torque values in this test
Test 4: Load Carrying – Tapping torque
Variocut G 613 HC (13 cSt)
Performance Bio NC Super Lite (8 cSt)
Performance Bio NC Ultra Lite (16 cSt)
Brand C: Mineral-based fl uid (15 cSt)
Performance Bio NC Lite (25 cSt)
Variocut G 600 HC (8 cSt)
Brand A: Plant-based fl uid (22 cSt)
Brand B: Plant fl uid (35 cSt)
Brand A: Plant fl uid (40 cSt)
Performance Bio NC Plus (40 cSt)
0 20 40 60 80 100 120 140
Torque (ncm)
Lower torque values are preferable
under the conditions of the test because
tool life benefi ts and/or surface fi nish
improvements can be achieved. Here,
Performance Bio NC Plus – again – is the
best overall performing fl uid with 7% less
torque required than the highest rated
alternative.
Brand B: Plant fl uid (35 cSt)
Variocut G 600 HC (8 cSt)
Performance Bio NC Plus (40 cSt)
Brand A: Plant fl uid (40 cSt)
Performance Bio NC Super Lite (8 cSt)
Variocut G 613 HC (13 cSt)
Performance Bio NC Ultra Lite (16 cSt)
Brand A: Plant-based fl uid (22 cSt)
Performance Bio NC Lite (25 cSt)
Brand C: Mineral-based fl uid (15 cSt)
0 0.2 0.4 0.6 0.8 1 1.2
Scar diameter (mm)
Test 5: Load Carrying – 4-ball
Excellent wear prevention
• Brand C’s mineral-based fl uid displays the
strongest properties in this wear test due,
in part, to its anti-wear additive content
• Performance NC Lite, Ultra Lite and
Super Lite display excellent wear
prevention, which underscores the
fl exibility of Performance Bio NC fl uids
across multiple viscosities
This metal-on-metal load test also
measures the lubricity properties of each
fl uid. A low number indicates good
performance (i.e. a low level of wear)
which, by association, can have a positive
bearing on tool wear and fi nish quality.
The results demonstrate that all
Performance Bio NC products perform well
under the test conditions.
Best overall performance
• Performance Bio NC Plus is the overall
‘best on test’ fl uid
• Performance Bio NC Plus outperforms
all other fl uids tested on fl ash point, air
release, tapping torque and evaporation
• Performance Bio NC Plus also achieves
good to excellent scores on the
remaining criteria: oxidation and
anti-wear properties
Consistency: Higher fi nish quality and accuracy
The data suggests that Performance
Bio NC products can offer comparable
performance to mineral-based fl uids, but
with cooler running temperatures, which
reduce problems of heat generation
affecting fl uid stability, and in turn,
workpiece quality and appearance.
Machinists may also encounter fewer
metal staining problems.
The following chart shows the median score of each fl uid, relative to the number of tests each product completed (i.e. not all
10 products completed all 7 tests). In each instance, the products were attributed a score 1-10 refl ecting their results ranking.
So, the best performing fl uid was allocated a maximum 10/10; while the worst ranking products would receive only 1/10.
A high number indicates superior performance across most test criteria:
oVeRaLL PeRFoRmance anD KeY taKeaWaYs
Throughput: Improved speed and lower downtime
Through the use of Performance Bio
NC fl uids, operators may be able to
increase running or rotational speeds
while minimising mist and fl ashpoint
hazards. Manufacturers could benefi t
from higher throughput and productivity
improvements due to the ability to run
at higher speeds, which can reduce
downtime between jobs and extend
machine cycles.
Flexibility: Fewer interruptions, more choice
The versatility of the Performance Bio NC
products means they can be used on a
wide variety of metals and different cutting
tasks, reducing the need for changeover
between different fl uid types. Customers
specifying such fl uids may therefore enjoy
fewer interruptions to operations, more
tool and metal choices, plus a reduction
in product inventories.
Variocut G 613 HC (13 cSt)
Performance Bio NC Super Lite (8 cSt)
Brand A: Plant fl uid (40 cSt)
Performance Bio NC Lite (25 cSt)
Performance Bio NC Ultra Lite (16 cSt)
Brand A: Plant-based fl uid (22 cSt)
Brand C: Mineral based fl uid (15 cSt)
Variocut G 600 HC (8cSt)
Brand B: Plant fl uid (35 cSt)
Performance Bio NC Plus (40 cSt)
0 2 4 6 8 10
Total score (average across all tests)
Performance characteristics
Excellent cutting performance Lower mist Low smoke Improved stability
Primary benefits
Better tool life, higher-quality finish
Reduced consumption, improved working environment
Improved flammability, better tool life/productivity
Lower maintenance, more reliable performance
NC Plus Cast iron
Low-medium alloyed steel
High alloyed steel/nickel-
chromium alloys
Titanium alloys
Aluminium alloys
Yellow metals
Honing / Superfinishing
– – – – – –
Grinding – – – – – –
Drilling ** * – * ** *
Broaching * * – ** ** **
Gear manufacturing
** ** * ** ** **
General machining
** ** * ** ** **
NC Lite Cast iron
Low-medium alloyed steel
High alloyed steel/nickel-
chromium alloys
Titanium alloys
Aluminium alloys
Yellow metals
Honing / Superfinishing
* ** * * ** **
Grinding * * * * * *
Drilling * * – ** ** **
Broaching * * – ** ** **
Gear manufacturing
** ** – ** ** **
General machining
** ** – ** ** **
For a more detailed breakdown of the four Performance Bio NC fluids, please refer to the tabulations below.
Performance Bio NC Product Applications
** suggested application * possible application (please refer to Castrol representative prior to use)
in Focus: PeRFoRmance Bio nc
NC Ultra Lite Cast iron
Low-medium alloyed steel
High alloyed steel/nickel-
chromium alloys
Titanium alloys
Aluminium alloys
Yellow metals
Honing / Superfinishing
* * * * ** **
Grinding * * * * * *
Drilling ** ** – ** ** **
Broaching * * – ** ** **
Gear manufacturing
** ** – ** ** **
General machining
** ** – ** ** **
NC Super Lite Cast iron
Low-medium alloyed steel
High alloyed steel/nickel-
chromium alloys
Titanium alloys
Aluminium alloys
Yellow metals
Honing / Superfinishing
** ** * ** ** **
Grinding * * * * * *
Drilling * – – – ** **
Broaching – – – – ** **
Gear manufacturing
– – – – ** **
General machining
– – – – ** **
DRiVing a natuRaL aDVantage FRom Within castRoL’s neW cLass oF PeRFoRmance Bio nc FLuiDs giVes manuFactuReRs moRe choice When it comes to maKing ResPonsiBLe FLuiD seLection.
By looking to achieve a better balance
between factors such as performance,
value, safety and the operating
environment, this latest fluid technology
will help customers cut the compromise
on the factory floor.
Castrol sees the challenge that industry
faces and has turned it into an opportunity
to move forward together. The result is
Castrol Performance Bio NC fluids.
PeRFoRmance Bio get a natuRaL aDVantagewww.naturaladvantage.castrol.com