FORGING LUBRIFICANTS FOR THE HOT FORGING OF STEEL.ppt

FORGING LUBRIFICANTS FOR THE HOT FORGING OF STEEL

1. 1
FORGING FORGING
LUBRICANTSLUBRICANTS
FOR THE HOT FOR THE HOT
FORGING OF STEELFORGING OF STEEL
TheirTheir impactimpact in the forging quality, the in the forging quality, the
life of the dies and the manufacturing life of the dies and the manufacturing
of forged partsof forged parts

2. 2
IMPORTANCE OF LUBRICATIONIMPORTANCE OF LUBRICATION

In a Hot Forging process, DIE LUBRICATION In a Hot Forging process, DIE LUBRICATION
is the KEY for QUALITY and PRODUCTIVITY.is the KEY for QUALITY and PRODUCTIVITY.

Lubrication, however, is not an easy job and is Lubrication, however, is not an easy job and is
very dependant on the very dependant on the rightright selection of selection of
parametersparameters such as: such as:

Lubricant and application types.Lubricant and application types.

Team supervision and operator experience, even Team supervision and operator experience, even
when fully automated systems are employed.when fully automated systems are employed.

3. 3
BENEFITS WHEN FORGING BENEFITS WHEN FORGING
LUBRICANTS ARE USEDLUBRICANTS ARE USED

LUBRICATE LUBRICATE (reduce the friction metal to metal thus (reduce the friction metal to metal thus
allowing metal flow to occur in a smooth and controlled allowing metal flow to occur in a smooth and controlled
way)way)

RELEASERELEASE (make possible the removal of the forged part (make possible the removal of the forged part
from the die)from the die)

COOLING COOLING (remove undesirable heat from dies)(remove undesirable heat from dies)

PROTECTPROTECT (protect and as a consequence extend the die (protect and as a consequence extend the die
life)life)

4. 4
WHAT IS A FORGING LUBRICANT?WHAT IS A FORGING LUBRICANT?

A lubricant for forging dies is a chemical A lubricant for forging dies is a chemical
compound that has a formulation that makes compound that has a formulation that makes
possible the forging process to be carried out possible the forging process to be carried out
within the limits and parameters considered within the limits and parameters considered
paramount by the forging industry. paramount by the forging industry.

5. 5
Usual types of Forging LubricantsUsual types of Forging Lubricants

Graphite in water dispersions.Graphite in water dispersions.

Graphite in oil dispersions.Graphite in oil dispersions.

Synthetic compounds based on organic Synthetic compounds based on organic
salts.salts.

Solid lubricants dispersions based on Solid lubricants dispersions based on
MoS2, Boron Nitride, Glass.MoS2, Boron Nitride, Glass.

6. 6
What is What is GraphiteGraphite??
Graphite is one of Graphite is one of
the forms of the the forms of the
mineral Carbon. mineral Carbon.
Its origin might Its origin might
be natural or be natural or
artificial.artificial.

7. 7
Important properties of GraphiteImportant properties of Graphite

Geometry of the particles.Geometry of the particles.

Particle size.Particle size.

Degree of purityDegree of purity..

8. 8
Structure of GraphiteStructure of Graphite

9. 9
Differences between the natural Differences between the natural
graphite and the synthetic or graphite and the synthetic or
artificial graphiteartificial graphite

Differences are more in the productive Differences are more in the productive
process rather than in the structure. process rather than in the structure.
Properties are almost identical.Properties are almost identical.

Natural Graphite: mineral extraction.Natural Graphite: mineral extraction.

Artificial Graphite: Produced from Artificial Graphite: Produced from
petroleum cokepetroleum coke..

10. 10
Myths and Trues about Graphite IMyths and Trues about Graphite I

MythMyth

All graphites are All graphites are
equal?equal?

TrueTrue

Only natural or artificial Only natural or artificial
graphites of hexagonal graphites of hexagonal
and crhystalline and crhystalline
structure propertiesstructure properties
are appropriate. are appropriate.
Amorphous graphites Amorphous graphites
do not possess adequate do not possess adequate
lubricatinglubricating

11. 11
Myths and Trues about Graphite IIMyths and Trues about Graphite II

Is the particle size the Is the particle size the
“differential” among the “differential” among the
different graphites used different graphites used
by the Forging Lubricant by the Forging Lubricant
manufacturersmanufacturers??

True and false at the True and false at the
same time. Very small same time. Very small
particles are not always particles are not always
necessary in a given necessary in a given
formulation. The formulation. The
combination of particle combination of particle
size and contained size and contained
carbon contain is what carbon contain is what
really makes the really makes the
difference.difference.

12. 12
FORGING DIEFORGING DIE

13. 13
Inter relation of variables in the Inter relation of variables in the
forging process. Their impact in forging process. Their impact in
the adherence.the adherence.

Degree of dilution of the concentrate.Degree of dilution of the concentrate.

Density of the lubricant mist.Density of the lubricant mist.

Temperature of the die.Temperature of the die.

Pressure of the application of the lubricant over Pressure of the application of the lubricant over
the die.the die.

14. 14
TRENDS IN DIE LUBRICATION TRENDS IN DIE LUBRICATION
I.I.
Applicational aspectsApplicational aspects

Process automation to make possible the Process automation to make possible the
manufacturing of an increasing number of parts manufacturing of an increasing number of parts
per hour.per hour.

Application of the lubricant in the way of a spray Application of the lubricant in the way of a spray
atomization to make possible to penetrate the atomization to make possible to penetrate the
thermal barrier surrounding the dies and thermal barrier surrounding the dies and
simultaneously lubricate and cool the dies.simultaneously lubricate and cool the dies.

15. 15
TRENDS IN DIE LUBRICATION IITRENDS IN DIE LUBRICATION II
Applicational aspectsApplicational aspects

Use of robotics as main applicational equipment.Use of robotics as main applicational equipment.

Functional lubricating systems-Automatic refilling of Functional lubricating systems-Automatic refilling of
reservoirs.reservoirs.

Dosing systems.Dosing systems.

16. 16
FACTORS THAT HAVE FACTORS THAT HAVE
INFLUENCE IN THE DIE LIFEINFLUENCE IN THE DIE LIFE

Pressure forces applied to the processPressure forces applied to the process

Speed of the metal flow.Speed of the metal flow.

Type and composition of metals forged.Type and composition of metals forged.

Type of metals and treatments employed in the Type of metals and treatments employed in the
dies.dies.

Friction coefficient imparted by the lubricant.Friction coefficient imparted by the lubricant.

17. 17
How must the forging lubricant perform How must the forging lubricant perform
to promote an extended die lifeto promote an extended die life

In first place forming a bonded film over the working In first place forming a bonded film over the working
die surface.die surface.

Secondly imparting to the die surface a reduced Secondly imparting to the die surface a reduced
friction coefficient able to promote a smooth metal friction coefficient able to promote a smooth metal
flow.flow.

In third place imparting cooling properties.In third place imparting cooling properties.

In fourth place not generating build ups on the die In fourth place not generating build ups on the die
surfacesurface..

18. Working temperature of the Forging Working temperature of the Forging
LubricantLubricant

To perform within To perform within
accepted parameters the accepted parameters the
forging lubricant has to forging lubricant has to
function at temperatures function at temperatures
between 200 and 300 between 200 and 300
grades centigrades.grades centigrades...
18

19. 19
WHAT INFLUENCE THE HEAT WHAT INFLUENCE THE HEAT
REMOVAL OF THE DIESREMOVAL OF THE DIES

Density of the lubricant.Density of the lubricant.

Pressure of the lubricant Pressure of the lubricant
deposition over the dies.deposition over the dies.

20. 20
WHAT INFLUENCE THE WHAT INFLUENCE THE
FRICTION COEFFICIENT?FRICTION COEFFICIENT?

Adherence of the lubricant film to the dies.Adherence of the lubricant film to the dies.

Type and characteristic of the lubricant Type and characteristic of the lubricant
used.used.

21. 21
What influences the die temperature?What influences the die temperature?

Mass and contact time of the billet over the dies.Mass and contact time of the billet over the dies.

22. 22
FACTOR NOT ALWAYS FACTOR NOT ALWAYS
OBSERVED IN THE OBSERVED IN THE
LUBRICATIONLUBRICATION

Quality of the water used in the dilution.Quality of the water used in the dilution.

Homogeneity of the diluted lubricant.Homogeneity of the diluted lubricant.

Variation control of the solid content prior toVariation control of the solid content prior to
the application of the lubricant. the application of the lubricant.

23. 23
Main ingredients of a Forging LubricantMain ingredients of a Forging Lubricant

Demineralized water.Demineralized water.

Crystalline graphite (natural or sinthetic)Crystalline graphite (natural or sinthetic)

Binding agents.Binding agents.

Stabilizers.Stabilizers.

Thickeners.Thickeners.

Bacteriological inhibitors.Bacteriological inhibitors.

24. 24
Die Termography - IDie Termography - I
-20
0
20
40
60
80
100
120
140
160
180
200
220
240
°C
239ºC
240ºC
216ºC

25. 25
Die Termography-IIDie Termography-II
-20
0
20
40
60
80
100
120
140
160
180
200
220
240
°C
239ºC
240ºC
216ºC

26. 26
DIE LIFEDIE LIFE
Important target to achieve:Important target to achieve:
Keep the total cost of the toolings below the 10% Keep the total cost of the toolings below the 10%
of the total manufacturing cost.of the total manufacturing cost.

27. 27
Lubrcation -Controls to make-I-Lubrcation -Controls to make-I-
In the concentrate product:In the concentrate product:
Control of the manufactures’s specificationControl of the manufactures’s specification
Type of graphite.Type of graphite.
Particle size.Particle size.
Ash content. Ash content.
Total solid content and graphite content. Total solid content and graphite content.
Viscosity and Ph of the concentrate.Viscosity and Ph of the concentrate.

28. 28
Lubrication -Controls to Lubrication -Controls to
make-IImake-II

In the diluted product:In the diluted product:

Chek that the solid content chosen is correct and keep it constant Chek that the solid content chosen is correct and keep it constant
during the product usage.during the product usage.

Check that the diluted product be under continuous agitation in Check that the diluted product be under continuous agitation in
the reservoir tank. the reservoir tank.

29. 29
Lubrication -Controls to make-IIILubrication -Controls to make-III
In and during its applicationIn and during its application

Time,angle,size of the lubricating drop,output and Time,angle,size of the lubricating drop,output and
distance from the lubricating point to the areas to distance from the lubricating point to the areas to
lubricate.lubricate.

30. 30
Lubricants -Controls to make -IV-Lubricants -Controls to make -IV-
In the lubricating unit (Robot)In the lubricating unit (Robot)

Time of positioningTime of positioning

Time of blow.Time of blow.

Time of retract.Time of retract.

Time of water cooling.Time of water cooling.

Output of water.Output of water.

Time of lubrication.Time of lubrication.

Output of lubricant.Output of lubricant.

31. 31
LUBRICATING SPRAY LUBRICATING SPRAY
ATOMIZATION DROP TYPESATOMIZATION DROP TYPES

32. 32
Interaction between the die Interaction between the die
and the billetand the billet
Extreme complexity because of:Extreme complexity because of:

Temperature and their control (variation in both).Temperature and their control (variation in both).

Transference of heat and its removal(billet cooling and Transference of heat and its removal(billet cooling and
heating and cooling cycles of the die)heating and cooling cycles of the die)

Time of contact billet/die.Time of contact billet/die.

Lubrication .Lubrication .

Die composition and treatments.Die composition and treatments.

33. 33
Technological barriers to overcomeTechnological barriers to overcome

Discovery of new ingredients/formulations that Discovery of new ingredients/formulations that
improve lubrication and reduce its incidence in the improve lubrication and reduce its incidence in the
factors affecting die life.factors affecting die life.

Better understanding between the relationship of the Better understanding between the relationship of the
lubricanting film and the die surface during the lubricanting film and the die surface during the
forging process.forging process.

34. 34
The forging techniques-To thinkThe forging techniques-To think

Despite forging is a technology with high Despite forging is a technology with high
experimental content, scientific reaserch is gaining experimental content, scientific reaserch is gaining
terrain in modern processes.terrain in modern processes.

As per the above concept, the continuous observation As per the above concept, the continuous observation
of the process by the operational base (machine of the process by the operational base (machine
operators, maintennance teams,etc) the accurate operators, maintennance teams,etc) the accurate
register of the process variables becomes register of the process variables becomes
IMPORTANT.IMPORTANT.

35. 35
Forged automotive partsForged automotive parts

36. 36
Hot upsetted pipesHot upsetted pipes

37. 37
Forgelube SRL de CVForgelube SRL de CV
www.forgelube.comwww.forgelube.com