Green Initiative at Automotive Transmission Gear Manufacturer
Reduces Total Operating Cost & Environmental Impact
Zero Gravity Filters (ZGF) installed a Maggie automatic magnetic separator and a Smart Drum PLUS fluid recovery system in a quench operation at a transmission gear manufacturing operation. The ZGF system is designed to remove scale from the quench water on a continuous basis. Since implementation, the ZGF Maggie system has provided the following benefits.
- Reduced water consumption by over 80%
- Reduced direct operating expense by over 90% (not including reduced heat load)
- Maintained established quality requirements
- Virtually eliminated direct operator interface thereby providing a safer work environment
- Eliminated landfilling of disposable filter media
- Reduced cooling requirements thereby reducing heat load to cooling towers
Process overview
Steel bars (i.e. bar stock) are fed into a machine at room temperature, and hot forged parts emerge at the other end.
Process Description
The bar stock is rapidly heated to temperatures in excess of 1200 C using high powered electric induction coils. The bar stock is sheared into blanks and then formed. The hot forged are then quenched in water. The scale that is deposited in the water is removed on a continiuos basis by the ZGF Maggie system. The ZGF Maggie system is fully automatic and does not use disposable media.
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