COST REDUCTION IN HOT FORGING.

by S. P. Shenoy*
C.E.O. STEEL PLANT SPECIALITIES 211, Raikar Chambers, Govandi East, Mumbai 400 088 Tel. : 022 - 6797 8060 Fax : 91-22-2555 2459 E-mail : info@steelplantspecialities.com Website : www. steelplantspecialities.com

Mr. S.P.Shenoy M.Tech. (Met.) MIIM

Hot forging is the controlled plastic deformation of heated metals and alloys into desired shapes. Deformation may be accomplished by means of pressure, impact blows or combination of both. In these processes, the friction between workpiece and die is a significant factor. In many cases, it may determine success or failure. Die cost amounts to 10% to 15% of the forging cost. Any improvement in the die life would automatically result in improved productivity and profitability of the forge shop. In closed-die forging, the metal must flow to fill the die without integral defects such as laps. The following factors contribute to adequate die filling: 1. Correct die design, especially proper draft, corner radius and fillet. 2. Reduction of friction by the use of polished dies and suitable lubrication. The loads set up during forging must not exceed the strength of the tools. The frictional constraint increases very rapidly when the stock to be compressed becomes thinner and of larger area.

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The forging load may become excessive unless the coefficient of friction is kept small. Also, sticking of the workpiece to the die cavity reduces productivity. Die life reduces considerably. Under these circumstances, adequate lubrication becomes very essential. IMPORTANT ROLES OF DIE LUBRICANT : 1. Reduction in forging load. 2. Improvement of uniformity in metal flow. 3. Prevention of sticking of forged component into the die cavity, thereby increasing the die life.

REQUIREMENTS OF A DIE LUBRICANT : A good lubricant should basically 1. 2. Minimise friction between the workpiece and the die. Function as a parting compound to permit separation after the part has been forged. 3. 4. 5. 6. Be readily removable from the workpiece. Be non-corrosive to the die, workpiece and forging equipment. Be non-pollutant. Avoid explosion due to rapid phase change.

Lubricant is either sprayed or swabbed onto the hot dies. Ordinarily, dies are sprayed manually, although some installations use automatic sprays that are timed with the press or hammer stroke. Deeper cavities may require the use of a supplemental spray to ensure coverage of all surfaces.

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The amount of lubricant to provide an optimum thickness of the film in the die cavity varies with the work metal. Excess lubricant is wasteful, dirties the area and the workpiece and pollutes the atmosphere. Recent trend is shifting towards the use of graphiteless lubricant with water as diluent due to its ability to control pollution.

LUBRICANTS IN THE INDIAN FORGING INDUSTRY : Many forge shops in India use furnace oil as lubricant. They are realizing day by day that it is a wrong practice. First of all, furnace oil is not a lubricant. When it comes in contact with the die surface which is at temperatures up to 5000 C, the hydrocarbons present in it burn out partially. The gas pressure generated between the forged component and the die wall give rise to hairline cracks. These cracks grow fast during subsequent operations of the forging hammer or press. The serrations so generated in the die cavity impair the surface finish of the forgings. Due to incomplete combustion of the hydrocarbons, a lot of smoke is generated. Sulphur present in the furnace oil enhances pungent smell of the smoke. This smoke is carcinogenic. Workmen feel tired soon and their efficiency is affected. Sooner or later, Pollution Control Board would raise serious objections to the use of furnace oil for swabbing the dies. Fortunately, a range of alternatives are available today. TYPES OF LUBRICANTS: 1. Water miscible, with graphite. 2. Water soluble, without graphite. 3. Oil based, with graphite. 4. Oil based, without graphite.
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Table-1 gives several benefits of using water miscible lubricant. In case of graphite containing lubricants, purity and particle size are important factors. Graphite based lubricant is popular throughout the world due to low cost. Certain problems are being experienced by modern press operators. First, the graphite particles fly off and damage the electrical system. Secondly, graphite particles accumulate on shop floor and pose the risk of slipping to the people moving around, irrespective of their status.Thirdly, special equipment is required with continuous stirring to prevent settling of graphite particles. Hence, graphiteless, water soluble lubricant is gaining ground. Due to complete solubility in water, settling problem is absent. Mild to nil agitation is adequate. Thickness of film is controlled by varying the dilution ratio or by incorporating suitable pigment. In the case of aluminium and brass forging, water soluble, graphiteless lubricant gives additional benefits. Due to absence of graphite, cost of cleaning the forging is considerably reduced. Productivity of the forge shop is enhanced. Selection of right type of lubricant is based on depth of die cavity, size and complexity of the forging, commitment to cost reduction and pollution control. Figure-1 explains how solving a problem (pollution control) simultaneously gives other benefits like cost reduction and improved customer satisfaction. Table-1 gives economical justification for using water miscible lubricant. Table-2 gives guidelines for selecting proper die lubricant.

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SUMMARY :
1. Use of right type of die lubricant is a decisive factor in the success of closed-die forging. 2. Use of furnace oil as a lubricant in hot forging should be prohibited since it pollutes the atmosphere and causes carcinogenic diseases to the workmen. Effective alternatives are available. 3. With the introduction of sophisticated forging equipment, die lubricant continues to retain its significance. 4. Indian Forging Industry can look forward to the availability of a range of indigenously developed lubricants which give all-round benefits.

Figure 1: Benefits of a water miscible hot forging lubricant:

Table-1: Justification for using ESPON-LSS water miscible die lubricant.

A case study:

Sr.No. 1.

Particulars Price

Furnace Oil Rs.27/- per litre

ESPON-LSS Rs.8/- per litre of solution prepared by mixing paste with water (1:15) 4500 (80% improvement)

2.

Die Life
Forging : Pump Housing Highly complicated profile forging

2500

3.

Method of application Pollution

Manual swabbing

Spraying

4.

Obnoxious, carcinogenic smoke.

Zero pollution. Clean environment.

Note : The single step of switching over to water miscible lubricant has resulted into substantial reduction in die cost, pollution control, productivity improvement and improved customer satisfaction.

Table-2 : Guidelines for selecting proper Die Lubricant

Sr. No. 1.

Application

Type of Lubricant

Product Name ESPON- LSS ESPON- GLF3

Shallow cavity dies.

Water miscible, with graphite Water soluble, without graphite

2.

Deep cavity dies, profile forgings

Oil based, with graphite

ESPON-DLO/V

3.

Stainless steel forgings

Oil based, with graphite

ESPON-DLO/V

4.

Brass forging

Oil based, without graphite

ESPON-BFL3

5.

Aluminium forgings

Water miscible, with graphite Water soluble, without graphite

ESPON-AL ESPON-GLF3

6.

Copper Forging

Oil based, with graphite and ESPON-DLO/V special additives