Modern low-friction gear oils

The MOTOREXenvironmentalpolicy

Heja MOTOREX!

Combined competence in machining and fluids

www.motorex.com

EXPORT

INDUSTRY

WHAT’S NEW

INSIDE

magazinemagazineNo. 69/20August 2003

Power pack!

BUCHER AG LANGENTHAL, MOTOREX LubricationCH-4901 Langenthal, www.motorex.com

IMPRESSUM

Dear readers,

“Know thyself”

These are the words that have stood over theentrance to the temple of Apollo in Delphi forthousands of years. This ancient inscription is astrue as ever and should still be placed over theentrances to corporations and executive suites.So why are so many companies in trouble today?While the economy was humming, egotism andarrogance pushed good business practices andcommon sense out the door. Often, only a pileof smoking rubble was left.

By contrast, we are a traditional Swiss family-owned business, and as business people we havebeen personally responsible for the past 86 yearsfor all our own actions, for our 200-plus em-ployees, indeed for our very existence. Honestyand reliability, close customer relations and con-tinuity are important values to us. We operate at a profit, so that we can continue to generateour growth through internal resources.

A healthy tradition and progress are notmutually exclusive, as the many new productsand innovations in this latest MOTOREX magazine

attest. Our newly formulated MOTOREXenvironmental policy shows how we view thebalance between ecology and the economy.

Trust is not something you can demand; it is something that develops mutually on bothsides of a relationship. I would like to personallythank you for the gift of placing your confi-dence in MOTOREX.

Sincerely,

Peter Regenass-BucherChairman of the Board of Directors

C o n t e n t s

3

What’s new A lot of energy is lost on theroute from the engine through the drive train to the wheels.We show you to avoid losing this energywith MOTOREX LongLife low-friction gear oils.

Industry Nowadays, the only way to machine castingseconomically but withhigh precision is to com-bine expertise in machinetools and in machiningfluids.

MOTOREX NEWS 4/5

PRO TEX – protection for textiles and leather

KTM hits the road

Neat and handy:the MOTOREX oil bag

Always essential:helmet and visor care

MOTOREX JET X-TREME BIO 2T

Oil included when you buy a KTM

MOTOREX with Phonak Cycling Team

MOTOREX SWISSLINE at KBA

WHAT’S NEW 6

LongLife low-friction gear oils for cars and trucks

INSIDE 7

MOTOREX’s living environmental policy

MOTO LINE 8

Air filter care using the TwinAir® system

HIGHLIGHT 89

The final touch: WHEEL CLEANER

EXPORT 10/11

Heja MOTOREX! A portrait of the MOTOREX importers in Sweden

INDUSTRY 12/13

Combined competence in machining and lubrication

BOX 14

Cool ideasDid you know. . .Comic

PAGE 6

Oil of Switzerland

E d i t o r i a l

PAGES 12/13

Inside We do more than just pay lip service to sus-tainable development and environmental protection atBUCHER MOTOREX – our recently published environmen-tal policy once again documents MOTOREX’s credibility.

PAGE 7

MOTOREX® and all employed productnames are internationally protectedtrade marks.

No responsibility is accepted for printingerrors or changes in the technical data. www.motorex.comwww.motorex.com

Editor:BUCHER AG LANGENTHALMOTOREX LubricationCH-4901 Langenthal

Tel. ++41 (0)62 919 75 75Fax ++41 (0)62 919 75 95

Customer service by phone. Advice and problem solving also in German,French and Italian.

Design, redaction and creation:Martin Aeschlimann, Advertising Concepts and Public Relations, Muri/Berneae-werbung@bluewin.chTranslation: BMP Translations AG, BaselGraphics and prepress: Sicolith AG,WabernPrinting: Benteli Hallwag AG,WabernText contributions may be used when source is indicated.Cover picture: Mapal Präzisionswerkzeuge Dr. Kress KG, Aalen/D

N e w s

5

MOTOREX JET X-TREME BIO 2T:Fewer emissions for more jet ski enjoymentAchieving top performance in sport is always amajor challenge for man and machine. With itsester-based JET X-TREME BIO 2T fully syn-thetic high-performance 2-stroke engine oil,

MOTOREX is also leading the way in cutting exhaust emissions. The rapidly bio-degradable lubricant is totally clean-burning, leaving no residue and producing very little smoke (JASO LOW SMOKE).

Ultramodern additives guarantee effective protection against corrosive agents including salt water and when service lives are long or periods of usage short.MOTOREX JET X-TREME BIO 2T meets manufacturers’ latest specificationsand is ideal for injection or premix lubrication in all jet skis.

It’s always the right time to learn moreabout the MOTOREX oil bag. This handy oil bag is custom-designed to holda MOTOREX 1-liter oil bottle with itsbuilt-in filler, plus an additional productsuch as MOTOREX WIPE & CLEANconcentrated windshield cleaner.

Even though most motor oils can bemixed nowadays, it’s a good idea whentopping up to pay attention to the gradeof oil you’re using and any specific

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MOTOREX PRO TEX provides highlyeffective, long-lasting protection againstwater, dirt and oil. Simply spray it onfrom the generous 500-ml spray can to protect all fabrics and materials in-cluding your riding leathers, your con-vertible top, or even an umbrella.

Once you’ve treated the articles withMOTOREX PRO TEX, dirt and soiledareas can be cleaned up easily and gently. Before you know it, the article is as clean as new.

Try some now!

MOTOREX’s international collabora-tion with KTM extends far beyond theconfines of motor racing – it’s bringingbenefits all the way down the line to the consumer too. Lucky buyers of anew KTM motorbike receive a voucherfor a free top-up of the appropriateMOTOREX engine oil from the inter-nationally renowned MOTO LINE.

The vouchers can be exchanged at authorized KTM dealers. Owners of two-stroke bikes get a liter ofMOTOREX CROSS POWER 2T,

manufacturer’s approvals. Always think about topping up with MOTOREX, sincethis is the only way to guarantee that thecomplex oil formulation remains in properbalance. For extra-easy access, the oil bagis equipped with a full zipper. In addition,strong hook-and-loop closures ensure that the bag remains securely attached,even on winding roads.

Your MOTOREX dealer can tell you more about the MOTOREX oil bag.

Neat and handy: the MOTOREX oil bag

Free oil top-up when you buy a KTM

D E G R ADAB L E

Protection for textiles and leatherThere are always situations in which wellimpregnated textiles and leather surfaces are worth their weight in gold.

Bull Road Racing Team, already hasseveral races under its belt, and, under the leadership of Harald Bartol, is fight-ing hard to get championship points.

The reigning world champion ArnaudVincent (F) and his teammate RobertoLocatelli (I) had to get used to the newKTM racing bike from Mattighofen, but they were immediately thrilled by the technical innovations on the power-ful RRF/2003.

MOTOREX is supporting the team as a technical sponsor by providing race-tested lubricants and power-packed know-how.

A really importantadvancement was made at the start of thisyear’s racing season: KTM decided to enterthe 125-cc road racing class. The team,which goes under the name of KTM Red

In the world of international road racing,the names of the Phonak Cycling Team’stop riders are ringing in everyone’s ears.The team’s technical partner isMOTOREX with its BIKE LINE. Theteam consists of 25 riders in the Swiss GS-I category. Top cyclists such as the 1998world champion Oscar Camenzind (Swit-zerland), Alex Zülle (Switzerland), BenoîtSalmon (France), Massimo Strazzer (Italy)and many others are guaranteed to makethe 2003 season an exciting one.

BIKE LINE in World Cup races

There have been a number of victories to celebrate and new challenges for lubricationtechnology to overcome since the compre-

the fully synthetic high-performance two-stroke oil, while for four-stroke enginesthere’s two liters of POWER SYNT SAE10W50. So, after factory filling KTM bikes can keep running perfectly withMOTOREX.

MOTOREX SWISSLINE at KBAThe German Koenig & Bauer Group is one of the world’s biggest manufacturers of print-ing presses, with the broadest product range inthe industry. Its parent company is Koenig &Bauer AG (KBA), which was founded in 1817and operates a global network of companies inaddition to several large production facilities inGermany. The core companies of the KBAGroup employ around 7,400 people.The Group’s Frankenthal plant in Ludwigs-hafen am Rhein has recently started using pro-ducts from MOTOREX’s successful SWISS-LINE range. Some 1,350 employees at Fran-kenthal build the world’s widest illustrationrotogravure presses and high-speed folders for all KBA rotogravure machines. It just goesto prove that you can’t keep a company likeMOTOREX out of the press!

Always essential: helmet and visor careEveryone’s out and about again: bikers . . .and those annoying insects! But MOTOREX knows how to deal with the swarming hordes. Use MOTOREXHELMET-CARE to quickly and gently remove even dried-on insects and hard-to-shift dirt from your helmet. HELMET-CARE also brightens up colors and provideslasting protection for the helmet surface.Plus, this special foam also effectively cleansand deodorizes helmet liners.

For cleaning sensitive visors, theMOTOREX product range includes its convenient VISO-CLEAN cleaning wipes. They’re handy to take along on tripsto make sure your visor stays clear and free of smears and dirt build-up.

MOTOREX wishes your customers safe and fun biking with HELMET-CARE andVISO-CLEAN!

hits the road

hensive on-road and mountain bike productrange was introduced in 1999. Whether onor off the road, in international competitionor on a Sunday afternoon pleasure outing,the MOTOREX BIKE LINE has the rightsolution for cyclists everywhere. And what’smore, most of the active constituents arerapidly biodegradable under current CECand OECD standards.

Find out more about the team at www.bmc-racing.com and www.phonak.ch

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O.B

erga

mas

chi

specimen

I n s i d e

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Used brake fluid is collected and con-

verted to valuable basic molecules for use

in the manufacture of plastics.

W h a t ’s n e w

6

higher performing; which means stricterspecifications for modern transmissionoils. Working together with vehiclemanufacturers, MOTOREX produced anew generation of transmission oils,which are making a significant contribu-tion to your car’s ecoefficiency.

LongLifelow friction-gear oils

A total of 15 tank cars transport the base

oils used by MOTOREX via the most direct

route possible from the refinery to our

storage tanks in Langenthal.

All of us have certainly asked ourselves on various occasions what our world will looklike tomorrow or beyond. Our ultimate goal, however, is to make certain that planetEarth will remain a wonderful place for future generations to live. All the employees ofthe BUCHER-MOTOREX group are committed to this principle, and truly sustain-able development lies at the center of all our activities.

Our responsibility to our environment is of central concern, both at the workplace andin our private lives. We are guided by the following principles:

• Our environmental policy encompasses every area of the BUCHER-MOTOREX groupand serves as a guiding principle in all our industrial processes.

• We develop, sell, and produce MOTOREX products that are safe to manufacture,safe to use, safe to recycle, and safe to dispose of.

• We minimize the burden on human beings and on the environment in the manu-facturing, storage, sale and use of our MOTOREX products.

• Each day we strive to produce as little waste as possible, to conserve resources,and to keep emissions low.

• Economic concerns, safety, environmental protection and health all enjoy the samehigh status in our MOTOREX strategy.

• We are continually striving to improve safety, health, and environmental protection.We accept this responsibility voluntarily, without being forced to do so by laws or government regulations, and we regularly invest significant sums of money in these areas.

• We seek an open, constructive dialogue with our partners, with governmental agencies, and with the public. Our goal is to promote mutual understanding andcreate trust in the BUCHER-MOTOREX group.

It goes without saying that MOTOREX’s environmental policy is continually beingmodified to take on board new achievements, discoveries and suggestions for improve-ments from our employees. MOTOREX’s environmental policy needs to be a vibrantand perceptibly efficient commitment.

Pict

ure:

BASF

• Maximum shifting comfortTotally smooth shifting over the entire temper-ature range (–40 to +120°C).Even at wintrytemperatures, manual shifting does not requireany noticeably greater force, nor are any low-temperature-induced rubbing and scratchingnoises audible.

• Reduced noiseWhining, humming, or grinding transmissions are out of place in high-tech vehicles.

• LongLife oil change intervalsIn modern transmissions, peak temperatures ofup to 135°C may be encountered.At these tem-peratures, the lubricant must fully retain all of itsproperties and must do so over its full service life.

• Fuel economyThe design and lubrication of differentials andmanual transmissions help to save fuel (low-fric-tion transmission oils).Lower friction losses canimprove fuel consumption by 0.5–1.5%.

• Measurably more powerAs little torque (and therefore power and perfor-mance) are lost in the transmission as possible.

• Universal useManual and trans-axle transmissions and insome cases even hypoid rear axles can be opti-mally lubricated with just a single product.

100% FuelHeat– 50%

Mechanical power loss

Engine– 8.5%

Hypoid rear axle – 2.5%

Transmission– 1.5%

Synthetic base fluidsSemisynthetic and fully synthetic basefluids have played a crucial role in thebreakthrough in LongLife transmissionoils. MOTOREX high-end products arenow available with optimally matchedadditive combinations.

The following products have been espe-cially developed for large truck transmis-sions with extended oil change intervals:

The range of low-friction transmission oilsfrom the CAR LINE was already featuredin a previous edition.

The main properties are:

• MOTOREX PENTA TL SAE 75W/90Fully synthetic LongLife low-friction, high-performance transmission oil for trucks, GL-5,MB235.8, MAN 342 SL+, SCANIA STO 1:0(Transmission Oil STO 1.0, Issue 6), ZF TE-ML 07A, 12B, 16F, 17B

• MOTOREX PENTA SAE 75W/140Fully synthetic LongLife, low-friction, high-performance transmission oil for trucks, GL-5

• MOTOREX PRISMA TF SAE 75W/85Synthetic LongLife, low-friction, high-perfor-mance transmission oil for trucks (SyntheticPerformance, API GL-4, Performance Level:VOLVO 97’305 and VOLVO 97’307, MAN 341 TL,ZF TE-ML 02D, Eaton

Remaining power available to drive the vehicle

You’re driving your car and have filled upwith 60 liters of petrol. Your fuel economy is 10 liters/100 km, which means that youcan drive for 600 km. The vehicle’s powerbalance from the tank to the tires on the road is sobering: Of the energy that you putin your tank, only slightly more than a third,or 37.5%, is left to drive the vehicle. 62.5%is “lost” on the way and converted to heat.The transmission and rear axle together ac-count for up to 4% of this chain of losses.Transmission losses cost you the driverabout 2.4 liters of fuel! It’s easy to calculatehow much this costs you in your local cur-rency. If you are driving a truck, it wouldcost you twice as much to cover this loss.

What’s needed: new transmission oilsIn the past, an SAE 80W GL-4 standardtransmission oil was used in the manualtransmission, and an SAE 90 GL-5 wasused in the hypoid rear axle. However, withthe need to reduce fuel consumption, trans-missions have become smaller, lighter and

Remaining power = 37.5% MOTOREX’s living environmental policy

As a manufacturer of chemical

and industrial products, MOTOREX

is frequently asked about its envi-

ronmental policy. It’s a subject that

has always been of genuine concern

at BUCHER-MOTOREX and not just

an area to which lip service has to

be paid.

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:Sca

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9

H i g h l i g h t

The final touch:WHEEL CLEANER Automobile manufacturers and tradeassociations agree that an overly aggres-sive active ingredient should never beused just for the sake of maximum clean-liness. It goes without saying that whilemodern wheel cleaners have to be efficient in how they clean, they must never attack the corrosion protection and coatings on the wheel and wheel nuts.

Proper cleaning is importantSpray MOTOREX WHEEL CLEANER directly onto the dirty wheel. Then leaveit on the wheel for at least 5 and no morethan 15 minutes. The active ingredientmust not be allowed to dry in the sun.Especially dirty wheels can be cleanedwith a suitable brush and WHEELCLEANER. Then rinse off with plentyof clean water. High-pressure sprayersalso work well for this job, but make cer-tain that you use a low pressure setting orstand a good distance from the wheel.

Wheels can also be thoroughly cleanedon the inside when changing betweenwinter and summer tires. If you are sto-

ring wheels for the winter or summer,make certain that they stay dry.

Efficient and gentleThe newly formulated MOTOREXWHEEL CLEANER is intendedmainly for the final user – automobileowners. Because of its optimal, gel-likeviscosity, it adheres well to the wheeland doesn’t drip off, so that it has timeto put its cleaning action to work. The resealable 500-ml spray appli-cator sits comfortably in the hand andis easy to store.

For professional wheel cleaning in repair shops, etc., MOTOREX also offers a different product formu-lation.

You can have clean wheels without poluting the environement – and ourWHEEL CLEANER from the com-prehensive MOTOREX CLEAN & CARE line of car care products proves it.

Be sure to pass this information on to your next customer!

Alloy wheels dazzling in the sunlight

are a sight to behold – if they’re really

clean, that is. Residues like brake

dust or road dirt need to be removed

properly at regular intervals.

Spray onto the entire wheel and leave

for at least 5 but no more than 15 minutes.

Use a suitable brush or sponge to remove

sturdy dirt and grime together with the

WHEEL CLEANER.

High pressure sprayers should only be used at

low pressure or a good distance from the wheel.

TwinAir® was founded more than 30 yearsago. At that time, the standard-productionpaper filters that were being used on off-road motorcycles were simply unable tocope with Holland’s sandy terrain, and theincreased engine wear showed it. After just30 minutes the filters were clogged, andthe race was over for some riders.

Thanks to a special laminated foam, TwinAir® soon conquered the air filtermarket, and it was not long before its specialist products had replaced conven-tional filters. The advantages of the newproduct were obvious: Because of thelonger service life and the good airflowthrough the filters – means that there is extra engine power – plus the perfect filtering, TwinAir® became a must on every racing bike.

Proven 1000 times over. . .Today, TwinAir®, together with the accompanying filter care program, is theworld market leader in offroad air filters.All of the major motocross racing teams,such as American Honda and Suzuki, Kawasaki JdG, Yamaha Rinaldi, BerniHonda Racing, KTM Racing, and manymore rely on the products from Veghel,Holland.

. . . and re-useable again and again.In contrast to paper filers, foam filters canbe cleaned and reused. For this reason,MOTOREX has integrated the TwinAir®-Bio Dirt Remover cleaner and the speciallyformulated TwinAir®-Liquid Bio Powerfilter oil in its well known MOTO LINE.Filters that have been maintained usingthis system reliably bar any dirt, dust, sandand water from entering the engine.

The TwinAir® product range includes very efficient cleaning and care productsand handy accessories such as convenientcontainers for cleaning and oiling the fil-ters. Whenever you work with these pro-ducts, be certain to follow the instructionsfor use on the back of the packaging. It isalso a good idea to always wear rubbergloves and safety glasses.

Biodegrades quicklyActive ingredients that biodegrade quickly are ideal for efficient cleaning and protection. This makes especiallygood sense when products are often used outdoors and, by mishap, occasio-nally have a close encounter with theenvironment.

All products are available in well-stockedmotorcycle shops. For additional suppliers,see www.twinair.com

M o t o L i n e

108

The cleaned and dried filter is then care-

fully dipped into the air filter oil and the

excess oil is squeezed out.

After being left to lie in TwinAir® Bio Dirt

Remover for about 15 minutes, the air filter

is thoroughly rinsed out with clear tap water.

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:Tw

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D E G R ADAB L E

In the motorcycle scene,

TwinAir® is the last word in

foam air filters and their care.

MOTOREX now offers biode-

gradable cleaning and care

products for TwinAir®.

Systematic air filter care

E x p o r t

Heja MOTOREX!

10

E x p o r t

In Sweden there are countless of ways toget about. Off-road and highway motor-cycles are popular, as are snowmobilesand, in summer, mountain bikes. Swedenhas nearly 100,000 km of highways, and is one of the most heavily forested coun-tries in Europe. Only 9% of Sweden’s entire land mass is used for agriculture.Leading industrial sectors are steel, paper,textiles and, of course, the automotiveindustry. While Volvo is now a Ford sub-sidiary, the marque “Volvo” (Latin for “I roll”) still stands for outstandingly safe transportation with an unmistakablestyle. With a land mass of 449,964 km2

Sweden is roughly 10times larger thanSwitzerland.

A strong partner in the Far NorthMOTOREX was fortunate in its choice of importers: Scott Svenska AB is respon-sible for the MOTOREX MOTO andARCTIC LINES. Hallman Sports AB isresponsible for the MOTOREX BIKELINE. It's an especially good mix, sinceboth companies are real pros in their markets and their customer bases have been growing for decades. In addition,both companies are members of the Hall-man Group, which in turn belongs to

Eneqvistbolagen AB, which is publicly traded on the Stockholm stock exchange.Being members of the same group, bothcompanies are able to exploit many posi-tive synergies in marketing, logistics andadministration.

The two MOTOREX importers are based in a state-of-the-art office complexin Uppsala. In addition to modern officefacilities, the location provides over 5,000 m2 floor space with an automatedwarehouse, various showrooms and training rooms, all available around the clock.

Scott Svenska ABScott is a familiar brand name throughoutthe world and, as a wholesaler, marketsproducts in three different areas:

• SCOTT winter products – goggles,skis, poles, snowboards etc.

• SCOTT bikes and biking accessories• Hallman Motosport – motorcycle

accessories and equipment

The products are imported, stored and distributed to retailers in the cycle, sportsand motorcycle trades. Retailers are found

In Sweden as

elsewhere, mobility is an essential

part of modern life, so it’s not

surprising that the Swedes are often

on the move, either on or off the road.

MOTOREX, with its MOTO, ARCTIC,

and BIKE LINES, is an ideal travelling

companion.

all over Sweden, and the products are soldthrough field salesmen and participation invarious trade fairs around the country.

The company’s business goal is the long-term and profitable marketing of high-quality and image sports products to theleisure trade. This is accomplished by cre-ating trust among our customers throughhigh competence and service levels.

Hallman Motosports products were firstdeveloped in the mid-1960s when four-time World Champion Torsten Hallmandesigned the first products for motocrossriders. The Hallman Motosport productline includes everything from clothes and accessories for road racing to exclusive import of about a dozen well known brand names in the motorcycle trade. The MOTOREX MOTO and ARCTICLINES are perfect additions to ScottSvenska’s product range. Today, the com-prehensive range of MOTOREX lubri-cation and vehicle care products is an im-portant sales generator.

Hallman Sports ABHallman Sports AB is a distribution com-pany with its own agencies for cyclingaccessories and equipment for the bicycletrade.

The company is the exclusive importer of a number of brand name products fromleading manufacturers in the cycling trade,such as Shimano bicycle components andmany others. Shimano is Hallman Sports’major brand, which it has been distributingin Sweden since 1991. Shimano compo-nents are fitted as OEM parts on mostbicycle brands. In the autumn of 2000,Hallman Sports AB was granted the distri-bution rights for Shimano in Finland, and,in the spring of 2002, in Norway too.

Hallman Sports AB currently operates in Sweden, Finland and Norway. HallmanSports OY is located in Turku and has a

Company founder and 4-time

World Champion Torsten Hallman

on a 400-cc Husqvarna in 1972.

A key to successful distribution:

Hallman and Scott’s comprehensive

catalogues are produced annually.

showroom in Helsinki. The Norwegianoperation is a branch office of HallmanSports AB and has offices and a showroomin Oslo. Thus the MOTOREX BIKELINE is being distributed in Finland andNorway as well as Sweden.

Administration and storage are handled in Sweden, and the products are distri-buted from there to retailers in all threecountries. The company has its owntravelling sales staff for the respectivemarkets. Active marketing to retailersusing product presentations, catalogues,website, service courses and training hasmade the company the leader in theNordic market.

Colder than coldAs a leading Swiss manufacturer of lubrication and care/cleaning products,MOTOREX has an in-depth under-standing of the thermal loads to whichcomponents that need to be lubricated are exposed. This is an advantage that is fully utilized in product developmentand has been repeatedly tested under thetoughest service conditions, even in theFar North.

Of course, winter temperatures in Switzerland hardly compare with those in Sweden, which often fall to below– 40°C. But even these temperatures can be duplicated in the freezers at the Research and Development department in Langenthal!

11

Hallman Sports AB actively supports talen-

ted Swedish mountain bikers, which helps

to ensure good awareness of the MOTOREX

BIKE LINE.

The elk is the symbol of Sweden – and it

also lends its name to the familiar avoidance

maneuver, the so-called elk test.

With its ARCTIC LINE, MOTOREX demon-

strates its lubrication know-how under

extreme service conditions.

I n d u s t r y

13

The MAPAL precision step drillWith its high-precision adjustable and exchangeable indexable inserts with two cutting edges, the MAPAL precisionstep drill (diameter of the first step: 31.8 mm/30°, diameter of the second step:30 mm H6, and diameter of the third step:18 mm H6) which is being used to ma-chine the part shown here represents thelatest generation of cutting tools used tomachine EN-GJS-400-15 (GGG40). The unmistakable MAPAL principle, withone tip and three guide pads, delivers ab-solutely precise machining results. Thisdesign was implemented for all three stepsin this machining operation. Above all,the quality of circularity is significantlybetter than that produced by conventionalmulticut reamers. N6 surface quality canbe achieved without difficulty using theselected cutting lead at the guide pads.

The finely lapped Cermet guide pads are used to guide the tool precisely andprovide support in the bore. The cuttingfluid that is used is the key to this finalfunction. The use of high-qualityMOTOREX SWISSCUT TWIN 300cutting fluid greatly extends the life of the guide pads. This is due to the ex-tremely thin lubricating film between

the guide pads integrated in the main body of the tool and the wall of the hole,which effectively prevents wear.

Additional contributions to extending service life are made by the coating on the indexable inserts and by optimal alignment of the tool. Using the inte-grated MAPAL adapter, the precision step drill can be aligned to the nearestmicron both radially and relative to its angular position.

Significantly longer tool livesCompared to the machining of alumi-num, where cutting velocities of severalmeters a minute can be achieved, the machining time for cast iron is limited bythe material. This was the challenge thatfaced MOTOREX and MAPAL: Usingthe right tool and a machining fluid pro-perly matched to the application, cuttingvelocities and tool lives were noticeablyimproved.

With the chlorine-free MOTOREXSWISSCUT TWIN 300 high-perfor-mance cutting fluid, the experts were ableto concentrate on achieving high cuttingvalues with above-average surface quali-ties and the same long tool lives. Thecomplex chemical processes in the criticaltemperature ranges were supported by aspecial high-pressure additive, withoutwhich the desired result would not havebeen possible.

This example once again shows that there is a great deal of performance potential that can be unlocked in variousmachining processes when the right com-bination of tool and lubricant is found.

To learn more, click: www.motorex.com and www.mapal.ch

Valuable synergies can only be achieved

through close cooperation between tool

makers, machine builders, and lubricant

producers.

Three at one strike – this cutaway

model clearly shows what goes on

inside a valve block.

Unmachined valve block castings made of

EN GJS-400-15 (GGG40) arrive in mesh bulk

containers for machining in Frutigen.

I n d u s t r y

1012

The Bucher Hydraulics plant in Frutigenis one of four production sites; it focusesits activities on the development and pro-duction of a broad range of hydraulic val-ves and valve blocks. The hose-burst safetyvalve shown here is manufactured for theworld-renowned CASE and CATER-PILLAR excavators, and it must meet aseries of tough quality specifications. Since manufacturers are required to com-ply with precise dimensional specificationsthey are extremely interested in produc-tion cycle times and tool lives. This iswhere MOTOREX, working togetherwith the renowned precision tool makerMAPAL Schweiz AG, came to the rescueby putting synergistic effects to work in a unique way.

More and more spheroidal graphitecast iron being usedSpheroidal graphite cast iron belongs tothe iron carbon group of alloys. Unlikesteel, the carbon content of this materialcan be up to 4%. The properties of thematerial depend on the shape, distributionand size of the graphite and the metallicmatrix (ferrite and pearlite 1:100). Withductile cast iron (i.e. a material that canyield or flex under loads), the graphite

appears in spheroidal, ball-shaped form.The specific structure of the spheroidalgraphite cast iron results in particularlyadvantageous mechanical properties suchas high tensile strengths, good elongationat break, and extremely low notch sensi-tivity. In addition, the material offers goodvibration deadening and excellent limp-home characteristics. Furthermore, im-proved dense-feed characteristics producegreater manufacturing reliability.

Thanks to its excellent mechanical pro-perties, the material is suitable for high-stress parts such as safety parts used inautomobiles and engines, as well as forthin-walled, lightweight designs. However, a great deal of skill is required to machine it economically.

Nowadays, the only way to economi-

cally yet accurately machine castings

is to combine expertise in machine

tools and machining fluids.

If you can do this, you’ll be success-

ful before long!

MOTOREX SWISSCUT TWIN 300 cutting

fluid and the MAPAL tool significantly opti-

mize machining results.

Combined competence in machining and lubrication

Properties of EN-GJS-400-15 spheroidal graphite cast ironMaterial designation EN-GJS-400-15as per DIN EN 1563 (previously GGG40)

Tensile strength Rm N/mm2 400 – 550

0.2%-yield point Rp0.2 N/mm2 250 – 350

Elongation at break A5% 27 – 15

Brinell hardness HB 30 135 – 185

The proven MAPAL principle embodies

maximum precision:

Cutting tool tip (1) with guide pads (2).

A = support Fp = passive force

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• Optimized performanceguaranteed

MOTOREX AG LANGENTHALLubricationCH-4901 LangenthalTel. ++41 (0)62 919 74 74Fax ++41 (0)62 919 76 96www.motorex.com

The vmax technology.The vmax technology.

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Full steam ahead for241-A-65 and MOTOREX

Do you have a snapshot for the MOTOREX magazine? Send the photo (in 300 dpi high resolution if it is in digital format) together with

a short description to us at: BUCHER AG Langenthal, MOTOREX magazine, Postfach, CH-4901 Langenthal, Switzerland. Thank you!

28-year-old Franklin Dominguez (with thewhite hat) from the Dominican Republic isa former children’s and AA-league baseballplayer who learned to ride a motorcycle at the tender age of eight. He first startedroad racing in 1999 with the support of hisfather, famous local motorcycle mechanicand ex-racer Montolino Dominguez, andGeorge Butler of MOTOBUTLER, akeen motorcyclist and MOTOREX’s ex-clusive distributor in the Dominican Repu-blic. Butler has been running a road-racingteam since 1994. “MOTOREX is the only

oil I can trust”, says Franklin, who is chief mechanic at MOTOBUTLER and also chief mechanic of the MOTOBUTLER/MOTOACCION/MOTOREX racing team, which presently has 5 riders. “I’ve tested over 30 different oil brands for road and race applications, and MOTOREX is the only one to deliver the protection that today’s high-tech motorcycles with their high-revving engines need.”

We wish Franklin Dominguez all the best in his quest for the Superbike title!

!

For three years Switzerland has been home to Europe’s largestoperational steam locomotive, a French express engine whosenumber – 241-A-65 – has also become its name. It was built in1931 and was rescued by a Swiss team when it was withdrawnfrom service. The loco is now based in Burgdorf near Berne.Following extensive restoration in Germany, 241-A-65 was steamed for the first time in 32 years in autumn 1997. With a full head of steam and its tender coupled up, the 9-axle giantweighs in at around 200 tonnes and measures an impressive 25.96 meters. This 3,500 hp museum piece is kept in perfect running order by the dedicated enthusiasts of the 241-A-65 association.And, as you know, MOTOREX has the right solution for everylubrication need! Further information at www.241a65.ch.

Did you know that . . .. . . even Dominican racers rely on MOTOREX?

CAR LINE overallAir vents for optimal ventilation

Available in sizes 42 – 62.Article no. 4.89 + size

Baseball cap, sportBeige Tactel with embroideredMOTOREX logo, one size fits all.

Article no. 4.01A

Tough, new and very attractive!

CAR LINE work coatAvailable in sizes 44 – 60.

Article no. 4.90 + size

Baseball cap, racingTactel, basic colour green, with green panel, yellow cord and embroidered

MOTOREX logo, one size fits all.Article no. 4.01

MOTOREX work clothes offer maximum comfortand unsurpassed functionality. All clothes aremade of a high-quality, durable 60/40% cotton/polyester blend.This fabric is rugged and easy-care.• Fashionable, attractive design• Now with a mobile phone pocket• Typical MOTOREX cut for maxi-

mum freedom of movement• Outstanding workmanship• Adjustable cuffs• Velcro on all pockets• 2-color collar

CAR LINE bib overallsAvailable in sizes 42 – 62.Article no. 4.88 + size

For your order, please use the card in the center of this magazine. Please ask your MOTOREX importer about the availability, price and delivery time of theabove articles.Thank you.

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