In metal stamping, tooling components like dies and punches undergo high levels of pressure and friction, which can lead to significant wear and tear over time. This wear impacts product quality and results in increased maintenance and replacement costs for manufacturers.
Metal stamping lubricants play a crucial role in addressing these challenges as they reduce tool wear and subsequently help control operating and maintenance expenses. Not all lubricants are created equal, though. Specialized lubricants exist to enhance tool longevity and optimize operational efficiency.
In the hunt for effective lubricants, industrial stamping operations have sought for decades to eliminate oil-based stamping compounds but have found that most synthetics are ineffective due to inferior interfaces and corrosion challenges. New advanced oil-free lubricants such as Consultant Lubricants’ 3900 series, however, have changed the game by successfully replacing neat and water-soluble oils without sacrificing performance or protection.
Consultant Lubricants Inc. has a deep understanding of stamping lubricants and their nuances. For the past 50 years, the company has been developing a range of metalworking fluids specifically formulated for metal stamping and related forming operations. The resulting product portfolio focuses on custom engineered stamping compounds, fluids and specialty lubricants designed to improve part quality, extend tool life and optimize production efficiency.
The company’s signature formulas have evolved through decades of continually solving customers real-world issues on-site by leveraging the option of timely custom formula adjustments from their lab and dedicated technical support. There are literally “decades of science in every drop.”
At a nano level
The overriding goal for the press lubricant is to protect a stamping tool’s surface by creating a barrier between the tool and the metal workpiece. But unlike traditional lubricants that coat and cushion, the company’s advanced metal stamping lubricants interact with the metal surfaces at a microscopic level, creating a more precise and durable protective interface.
Nano-structured lubricants are made to “activate” at the molecular level by providing a continual interface barrier that minimizes the direct contact that leads to part galling, cold welding and surface imperfections, which results in optimum part quality.
Additionally, advanced lubricants provide a uniform, ultra-thin protective layer with low surface tension, preventing beading that reduces direct metal-to-metal contact. Repeated metal-on-metal contact causes surface damage, such as scoring, scratching, galling and chipping on the tooling components. Over time, this damage can compromise the tool’s ability to produce accurate and defect-free parts.
With advanced lubricants, the outcome is less wear on tooling components, which extends production uptime, minimizing costly maintenance. The lubricant is formulated to temporarily fill microscopic surface imperfections while reacting predictably to heat and pressure.
This advanced oil-free solution also adds to the cleanliness of a workspace. Traditional lubricants rely on thick, oily films that create a cleaning and safety hazard. But the micro-scale interaction approach means less product used and less residue so parts are easier to clean and can more readily advance to the downstream processes, like welding or coating, ready for processing. Many customers have discovered that they can fully eliminate the parts washing stage at the end of the press and proceed to secondary welding operations.
Reducing friction, heat
One of the primary functions of metal stamping lubricants is to reduce the friction between the tool and the metal workpiece. Without lubrication, the intense friction generated during the stamping process leads to excessive heat, which can affect part tolerance and tool accuracy.
This heat buildup accelerates tool wear, causing the edges to dull or deform. By providing a thin protective layer, metal stamping lubricants help reduce the friction and absorb some of the heat, preserving the tool’s structural integrity and slowing down wear.
Advanced nano-level lubricants, including those in Consultant Lubricants’ 3900 series, contain molecular structures that wet out and adhere to metal surfaces. This series’ ability to maintain a consistent interface between the tool and the workpiece helps reduce galling, friction and heat buildup.
Tool life support
The cost of replacing tooling and dies can be significant, especially in high-volume manufacturing environments where tooling must meet precise tolerances. Frequent tooling maintenance and coating replacements not only increase expenses but also lead to more downtime and impact productivity.
By using advanced metal stamping lubricants, manufacturers can extend the life of their tools, as the lubricants effectively reduce the wear that causes tools to degrade prematurely. Extended tool life means manufacturers can use their tooling for more production cycles before needing to replace or recoat it, which can result in significant cost savings over time.
When tools wear out or sustain damage, maintenance teams often need to step in to sharpen or repair them. Metal stamping lubricants help minimize these maintenance requirements by preserving the tool’s edges and reducing wear.
This means maintenance intervals can be stretched further, allowing for more continuous production and reducing labor costs associated with frequent repairs. Less frequent maintenance also means fewer disruptions in production schedules, leading to improved workflow and greater operational efficiency.
Consultant Lubricants’ custom-formulated products are tailored to match specific tooling and the materials and processes in which they are used, so manufacturers can drill into specifics before choosing a lubricant. For example, are they using steel or aluminum? Are the jobs deep-drawing or heavy-forming operations? Are they using progressive dies or involved in high-cycle stamping? And what are the specific downstream finishing requirements? Answering these questions will help manufacturers make an informed decision about their lubricants.
Steady production
Each time a tool requires maintenance or recoating of tool components, production must be halted, leading to costly downtime.
Consultant Lubricants formulates and manufactures a full spectrum of metalworking fluids, including vanishing oils, food-grade lubricants, machining and grinding coolants, and specialized lubricants for electrostatic or high-precision metal forming processes.
With metal stamping lubricants, the goal is to reduce friction and heat; extend tool life; improve part quality and forming accuracy; reduce scrap and maintenance; and support welding, coating or painting post-stamping. For manufacturers, the investment in quality lubricants translates into better productivity, lower expenses, improved operator safety and more.
As proven with this article, the science that goes into the production of metalworking fluids can be incredibly fascinating. For equally eye-opening information, visit Techgen’s Consumables page, which is overflowing with similar articles.
