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Forging Lubricants For The Hot Forging Of Steels
 

Forging Lubricants For The Hot Forging Of Steels

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Brief description on Forging Lubes and its importance in the Hot Forging Process of Steels

Brief description on Forging Lubes and its importance in the Hot Forging Process of Steels

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    Forging Lubricants For The Hot Forging Of Steels Forging Lubricants For The Hot Forging Of Steels Presentation Transcript

    • FORGING LUBRICANTS FOR THE HOT FORGING OF STEEL Their impact in the forging quality, the life of the dies and the manufacturing of forged parts
    • IMPORTANCE OF LUBRICATION
      • In a Hot Forging process, DIE LUBRICATION is the KEY for QUALITY and PRODUCTIVITY.
      • Lubrication, however, is not an easy job and is very dependant on the right selection of parameters such as:
      • Lubricant and application types.
      • Team supervision and operator experience, even when fully automated systems are employed.
    • BENEFITS WHEN FORGING LUBRICANTS ARE USED
      • LUBRICATE (reduce the friction metal to metal thus allowing metal flow to occur in a smooth and controlled way)
      • RELEASE (make possible the removal of the forged part from the die)
      • COOLING (remove undesirable heat from dies)
      • PROTECT (protect and as a consequence extend the die life)
    • WHAT IS A FORGING LUBRICANT?
      • A lubricant for forging dies is a chemical compound that has a formulation that makes possible the forging process to be carried out within the limits and parameters considered paramount by the forging industry.
    • Usual types of Forging Lubricants
      • Graphite in water dispersions.
      • Graphite in oil dispersions.
      • Synthetic compounds based on organic salts.
      • Solid lubricants dispersions based on MoS2, Boron Nitride, Glass.
    • What is Graphite ?
      • Graphite is one of the forms of the mineral Carbon. Its origin might be natural or artificial.
    • Important properties of Graphite
      • Geometry of the particles.
      • Particle size.
      • Degree of purity .
    • Structure of Graphite
    • Differences between the natural graphite and the synthetic or artificial graphite
      • Differences are more in the productive process rather than in the structure. Properties are almost identical.
      • Natural Graphite: mineral extraction.
      • Artificial Graphite: Produced from petroleum coke .
    • Myths and Trues about Graphite I
      • Myth
      • All graphites are equal?
      • True
      • Only natural or artificial graphites of hexagonal and crhystalline structure properties
      • are appropriate. Amorphous graphites do not possess adequate lubricating
    • Myths and Trues about Graphite II
      • Is the particle size the “differential” among the different graphites used by the Forging Lubricant manufacturers ?
      • True and false at the same time. Very small particles are not always necessary in a given formulation. The combination of particle size and contained carbon contain is what really makes the difference.
    • FORGING DIE
    • Inter relation of variables in the forging process. Their impact in the adherence.
      • Degree of dilution of the concentrate.
      • Density of the lubricant mist.
      • Temperature of the die.
      • Pressure of the application of the lubricant over the die.
    • TRENDS IN DIE LUBRICATION I.
      • Applicational aspects
      • Process automation to make possible the manufacturing of an increasing number of parts per hour.
      • Application of the lubricant in the way of a spray atomization to make possible to penetrate the thermal barrier surrounding the dies and simultaneously lubricate and cool the dies.
    • TRENDS IN DIE LUBRICATION II
      • Applicational aspects
      • Use of robotics as main applicational equipment.
      • Functional lubricating systems-Automatic refilling of reservoirs.
      • Dosing systems.
    • FACTORS THAT HAVE INFLUENCE IN THE DIE LIFE
      • Pressure forces applied to the process
      • Speed of the metal flow.
      • Type and composition of metals forged.
      • Type of metals and treatments employed in the dies.
      • Friction coefficient imparted by the lubricant.
    • HOW MUST ACT THE FORGING LUBRICANT TO PROMOTE NA EXTENDED DIE LIFE
      • In first place forming a bonded film over the working die surface.
      • Secondly imparting to the die surface a reduced friction coefficient able to promote a smooth metal flow.
      • In third place imparting cooling properties.
      • In fourth place not generating build ups on the die surface .
    • Working temperature of the Forging Lubricant
      • To perform within accepted parameters the forging lubricant has to function at temperatures between 200 and 300 grades centigrades. .
    • WHAT INFLUENCE THE HEAT REMOVAL OF THE DIES
      • Density of the lubricant.
      • Pressure of the lubricant deposition over the dies.
    • WHAT INFLUENCE THE FRICTION COEFFICIENT?
      • Adherence of the lubricant film to the dies.
      • Type and characteristic of the lubricant used.
    • What influences the die temperature?
      • Mass and contact time of the billet over the dies.
    • FACTOR NOT ALWAYS OBSERVED IN THE LUBRICATION
      • Quality of the water used in the dilution.
      • Homogeneity of the diluted lubricant.
      • Variation control of the solid content prior to
      • the application of the lubricant.
    • Main ingredients of a Forging Lubricant
      • Demineralized water.
      • Crystalline graphite (natural or sinthetic)
      • Binding agents.
      • Stabilizers.
      • Thickeners.
      • Bacteriological inhibitors.
    • Die Termography - I
    • Die Termography-II
    • DIE LIFE
      • Important target to achieve:
      • Keep the total cost of the toolings below the 10% of the total manufacturing cost.
    • Lubrcation -Controls to make-I-
      • In the concentrate product:
      • Control of the manufactures’s specification
      • Type of graphite.
      • Particle size.
      • Ash content.
      • Total solid content and graphite content.
      • Viscosity and Ph of the concentrate.
    • Lubrication -Controls to make-II
      • In the diluted product:
      • Chek that the solid content chosen is correct and keep it constant during the product usage.
      • Check that the diluted product be under continuous agitation in the reservoir tank.
    • Lubrication -Controls to make-III
      • In and during its application
      • Time,angle,size of the lubricating drop,output and distance from the lubricating point to the areas to lubricate.
    • Lubricants -Controls to make -IV-
      • In the lubricating unit (Robot)
      • Time of positioning
      • Time of blow.
      • Time of retract.
      • Time of water cooling.
      • Output of water.
      • Time of lubrication.
      • Output of lubricant.
    • LUBRICATING SPRAY ATOMIZATION WAYS OF THE DROP
    • Interaction between the die and the billet
      • Extreme complexity because of:
      • Temperature and their control (variation in both).
      • Transference of heat and its removal(billet cooling and heating and cooling cycles of the die)
      • Time of contact billet/die.
      • Lubrication .
      • Die composition and treatments.
    • Technological barriers to overcome
      • Discovery of new ingredients/formulations that improve lubrication and reduce its incidence in the factors affecting die life.
      • Better understanding between the relationship of the lubricanting film and the die surface during the forging process.
    • The forging techniques-To think
      • Despite forging is a technology with high experimental content, scientific reaserch is gaining terrain in modern processes.
      • As per the above concept, the continuous observation of the process by the operational base (machine operators, maintennance teams,etc) the accurate register of the process variables becomes IMPORTANT.
    • Forged automotive parts
    • Hot upsetted pipes
    • FORGING LUBRICANTS
      • GUSTAVO G.SCHIUMA
      • INTERNATIONAL REPRESENTATIONS
      • MARKET INTELLIGENCE
      • BRASIL: 5511-3044-7137/5511-9172-7769
      • ARGENTINA:5411-4773-9893
      • MEXICO:5281-8372-1358
      • INDIA : 91-22-2646141
      • Mail : [email_address]