COST REDUCTION IN HOT FORGING.

by

S. P. Shenoy*

C.E.O.
STEEL PLANT SPECIALITIES
211, Raikar Chambers,
Govandi East, Mumbai – 400 088 Mr. S.P.Shenoy
Tel. : 022 - 6797 8060 Fax : 91-22-2555 2459 M.Tech. (Met.)
E-mail : info@steelplantspecialities.com MIIM
Website : www. steelplantspecialities.com

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. Minimise friction between the workpiece and the die.

2. Function as a parting compound to permit separation after the

part has been forged.

3. Be readily removable from the workpiece.

4. Be non-corrosive to the die, workpiece and forging equipment.

5. Be non-pollutant.

6. 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. Particulars Furnace Oil ESPON-LSS

1. Price Rs.27/- per litre Rs.8/- per litre of

solution prepared by
mixing paste with
water (1:15)

2. Die Life 2500 4500

(80% improvement)

Forging :
Pump Housing
Highly complicated
profile forging

3. Method of Manual swabbing Spraying

application

4. Pollution Obnoxious, Zero pollution.

carcinogenic smoke. 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. Application Type of Lubricant Product

No. Name

1. Shallow cavity Water miscible, with graphite ESPON- LSS

dies.
Water soluble, without graphite ESPON- GLF3

2. Deep cavity Oil based, with graphite ESPON-DLO/V

dies, profile
forgings

3. Stainless steel Oil based, with graphite ESPON-DLO/V

forgings

4. Brass forging Oil based, without graphite ESPON-BFL3

5. Aluminium Water miscible, with graphite ESPON-AL

forgings
Water soluble, without graphite ESPON-GLF3

6. Copper Forging Oil based, with graphite and ESPON-DLO/V

special additives