November 2020 Volume 2

FORGING RESEARCH AND TECHNOLOGY

Substantial increase in die life after cold-welding: Substantial increase in die life after cold-welding:

S. No.

Description

of

Metal Forming Equipment

Not coated die life

Japanese cold-welded die life (No. of parts formed) 25900 1000 ton hot forging press 1600 ton hot forging press 1600 ton hot forging press 5400 1000 ton hot forging press

Percentage increase in die life

die/tool

(No. of parts formed) Hot forging die

2.

4000

5400

35%

Sheet metal pressing die & tool set

Sheet metal press (cold pressing)

1.

18500

40%

3.

Hot forging die

8000

12000

58%

4.

Hot forging die

10000

15900

62%

5.

Hot forging die

10000

22000

120%

1000 ton hot forging press 1000 ton hot forging press 1600 ton hot forging press 1600 ton hot forging press

2.

Hot forging die

4000

35%

3.

Hot forging die

8000

12000

58%

10000 Observation after implementing Japanese cold-welding technique: Demonstrations of this technique have shown encouraging results. Hence, there is no risk in terms of die/tool breakage or reduced life. The percentage increase in die and tool life has varied from as low as 35% in initial trials to as high as 120% in recent trials. Various parameters that contribute to the success of this technique are well documented, leading to refinement of the technique. 15900 62%

4.

Hot forging die

5.

Hot forging die

10000

22000

120%

Subject 2: Increasing die life using customized die lubricating equipment and environment-friendly die lubricants. Die lubricants play an important role in achieving optimum die life.

Observation after implementing Japanese cold-welding technique: Demonstrations of this technique have shown encouraging results. Hence, there is no risk in terms of die/tool breakage or reduced life. The percentage increase in die and tool life has varied from as low as 35% in initial trials to as high as 120% in recent trials. Various parameters that contribute to the success of this technique are well documented, leading to refinement of the technique. Observation after implementing Japanese cold-welding technique: Demonstrations of this technique have shown encouraging results. Hence, there is no risk in terms of die/tool breakage or reduced life. The percentage increase in die and tool life has varied from as low as 35% in initial trials to as high as 120% in recent trials. Various parameters that contribute to the success of this technique are well documented, leading to refinement of the technique. Subject 2: I c easing die life u ing cu tomized die lubricating equipment and environment-friendly die lubricants. Probl : Use of cheap oils when used as die lubricant leads to v ry l w die life and pollutes the forge shop. Water miscible graphite based lubricant is better than oils. However, graphite spreads arou d and makes the forge shop dirty. Being a good conductor of electricity, graphite damages the electrical equipment of modern forging presses. Observation: Many times, switching over from oil to water-based graphite or to synthetic lubricants is daunting. This is due to improper spray techniques, leading to low die life or die breakage as depicted. Subject 2: Increasing die life using customized die lubricating equipment and environment-friendly die lubricants. Die lubricants play an important role in achieving optimum die life. Problem: Use of cheap oils when used as die lubricant leads to very low die life and pollutes the forge shop. Water miscible graphite based lubricant is better than oils. However, graphite spreads around and makes the forge shop dirty. Being a good conductor of electricity, graphite damages the electrical equipment of modern forging presses. Observation: Many times, switching over from oil to water-based graphite or to synthetic lubricants is daunting. This is due to improper spray techniques, leading to low die life or die breakage as depicted. Technology: New generation synthetic die lubricants that are effective and clean are now available. Synthetic die lubricants have often proven better compared with graphite. This is possible only when synthetic lubricants are used with correct methods of spraying. Customized spraying systems and spray guns, depending on the specific forging profile, need to be used. Die lubricants play an important role in achieving optimum die life. Problem: Use of cheap oils when used as die lubricant leads to very low die life and pollutes the forge shop. Water miscible graphite based lubricant is better than oils. However, graphite spreads around and makes the forge shop dirty. Being a good conductor of electricity, graphite damages the electrical equipment of modern forging presses. Observation: Many times, switching over from oil to water based graphite or to synthetic lubricants is daunting. This is due to improper spray techniques, leading to low die l fe or die breakage as depicted.

FIA MAGAZINE | NOVEMBER 2020 105