Simple Solutions That Work! Issue 9

Lubricants play a critical role in the forging and casting industries. First of all, the lubricant prevents the metal of the cast or forged piece from sticking to the tool steel, allowing for effective release. Secondly, the appropriate mixture of lubricant and water performs as a cooling agent to maintain the optimum tooling temperature for proper metal fill or flow. Finally, the lubricant provides tooling protection through an applied barrier that minimizes the impact of the casting and forging process per cycle, and has a direct impact on the frequency of polishing and overall life of the tooling. Lubrication can affect productivity, component quality and even the lifespan of a die. Yet, the importance of optimizing the lubricant blend and delivery in a consistent, repeatable and accurate manner often times falls low on the priority list. Our experience has taught us that minor changes to the lubricant process can not only improve the quality of process and product, but also reduce lubrication and disposal fees. Once you’ve established the best lubricant for your application, the absolute most important rule is lubrication consistency. This begins with accurate and thorough mixing of the lubricant/water solution and then precise and accurate delivery. Simply stated, inconsistent lube dilution and application can result in erratic, unpredictable process and product. STEP 1: LUBRICANT MIXING Companies typically select a location central to production for mixing the lube:water ratio, where we find that hand mixing lubricant is still very common. And humans, being human, are inconsistent. We also often see the use of premixed lube solutions provided by suppliers. However, this approach means you pay not only to transport the lubricant to your facility, but also the water included in the mixture. With both of these approaches, when we’ve analyzed the mixtures using refraction – a measure of the solid content that can verify proper mixing – we typically notice some issues. First off, the mixtures tend to be too rich, meaning more lubricant is being used than necessary. Secondly, the mixture is inconsistent from batch to batch. You won’t reap the full benefit of your lubricants if you don’t first start off with a consistent, homogeneous mixture. Improperly prepared mixtures can separate before and during use, causing equipment to operate inefficiently. This leads to product quality issues while adversely impacting productivity and tool life, to say nothing of lubricant waste. This issue can be solved by mechanical mixing of lubricant, where the lubricant concentrate and water is accurately metered, systematically combined, thoroughly mixed and then dispensed into a transfer device. Additionally, our proportioners provide flexibility to make changes to the dilution, allowing the user to adjust to the requirements of varying manufacturing processes. STEP 2: PROPER APPLICATION The next step is to ensure your application is as accurate and consistent as your lube solution. Almost all companies err on the side of using more lubrication than necessary. This can be especially problematic with parts that have irregular features and varying wall thicknesses. With complex components, the instinct is to overspray the challenge areas. This can result in puddles of lube on the floor, which is both wasteful and dangerous. Even more importantly, over application affects the quality of TROY TURNBULL President INDUSTRIAL INNOVATIONS ARTICLE TAKEAWAYS: • Lubricants are for more than just release of a part • Part quality and tooling production life depend on proper lubrication • Lubrication consistency can reduce scrap PROPER PROPORTIONAL MIXING OF DIE LUBRICANTS AND DELIVERY 20