November 2020 Volume 2

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.

FORGING RESEARCH AND TECHNOLOGY

1050 0

Dry Graphite in machine oil

Load (Tonnes)

0 20 40 60

Reduction in Height %

Fig 1: Reduced forging load by using lubricant. Ref.: Dr. A. S. Deshpande, IIT, Mumbai, India. Fig 1: Reduced forging load by using lubricant. Ref.: Dr. A. S. Deshpande, IIT, Mumbai, India. Case Study I: Productivity Improvement due to reduced die grinding time by switching over to graphiteless, water soluble lubricant. Case Study I : Productivity Improvement due to reduced die grinding time by switching over to graphiteless, water soluble lubricant.

Sr.No.

Particulars

Graphite Based Die Lubricant

Graphiteless Die Lubricant

1.

Forging Equipment

1000 Ton Press

2.

Product

Forging Sleeve

3.

Dilution Ratio

1 : 10

1 : 10

4.

Time Loss Due to Die Grinding at Each Shift

1.5 hours

NIL

5.

Production in 3 shifts Productivity Improvement

7000

9000

6.

--

22%

FIA MAGAZINE | NOVEMBER 2020 106