Oil free (water-based) lubricant stamping oil improves production efficiency by 60%
April 08, 2023
The world's technology is changing, lubrication processes are changing, environmental protection and energy conservation are changing, and the laws governing the use of chemicals are also changing. Therefore, the principle of metal forming lubrication has also changed after years of use.
Water-based oil-free lubricants have successfully replaced 200 million gallons of oil-based lubricants in 32 countries and regions worldwide. It is the world's only patented technology formed through the use of cutting-edge technology to synthesize extreme pressure resistant polymers based on water. During the stamping process, a tough lubricating film is formed on the surface of the mold, solving the molding technology problems. Especially in the field of high-strength steel molding, it has comprehensive response capabilities. Combined with automatic spraying equipment, it achieves the molding requirements of stamping workpieces in a micro and efficient manner. At the same time, due to the small residual amount on the surface of the workpieces, The unique oil-free and non-toxic characteristics have enabled enterprises to meet various demands such as cleaning free welding, degreasing free cleaning, and mold protection. Overall, they have helped enterprises achieve efficiency improvement, cost control, quality assurance, and energy conservation and environmental protection. It has achieved a significant increase in punching times, from the original 42 times per minute to the current 68 times, increasing production efficiency by 60%, and extending the mold life by three times, reducing mold repair time and costs, highlighting advantages in lubricant usage and controlling labor costs. This article focuses on the differences between oil-free lubricants (also known as water-based lubricants) and water-soluble stamping oils from three aspects for reference.
Basic synthesis process Water soluble stamping oil: It is synthesized using mineral oil as the base material, adding emulsifiers, water, and rust inhibitors. At the same time, considering the different difficulty of workpiece forming, the proportion of mineral oil added varies for different models of products. Due to the biggest characteristic of the research and development background of water-soluble stamping oil, which is easy to clean or free from cleaning, a large amount of volatile substances need to be added to reduce residual products. Oil free (water-based) lubricant: synthesized with water as the substrate, adding high molecular weight extreme pressure resistant polymers, thermosensitive reaction polymers, and rust prevention factors. It is required to be free of any oil or volatile toxic substances. Technical performance
Water soluble stamping oil: 1. The solution is prone to delamination during storage or use; 2. It can meet the forming or drawing requirements of general workpieces, but it is difficult to meet or meet the requirements for heavy-duty, high-strength steel, deep drawing, etc; Long term use has a significant impact on the wear of the mold; 3. The cleaning process requires the addition of a large amount of degreasing agents and other chemicals, and the cleaning water temperature should generally be controlled between 50-60 ℃; Oil free (water-based) lubricant: 1. It can be fully mixed with water without sedimentation or stratification; 2. Due to the absence of any oil components, the cleaning process can be completely cleaned with room temperature water at 20-40 ℃, without the need to add any degreasing agents or related chemicals; 3. During the stamping process, due to the absence of grease in the lubricant, the hot melt is low, which can quickly form steam to remove heat, reduce mold temperature, and extend mold life; Therefore, it is of great help in improving the punching speed. Safety Water soluble stamping oil: This type of product usually has a short shelf life and is prone to fission during use, emitting a foul odor and having a significant impact on the production environment; At the same time, the addition of solvents, emulsifiers and other chemicals to the product can cause harm to the skin and respiratory tract; More importantly, some substances in the product are carcinogenic and must be strictly treated when discharged. At present, the testing reports usually provided for this type of product are mostly general technical performance testing reports, and there are no testing reports related to toxicity for users to refer to or use. Oil free (water-based) lubricant: this kind of product has a very long shelf life. Since water is used as engineering material and no toxic chemicals are added, it can be directly contacted with skin, and long-term use will not cause damage to human organ such as respiratory tract. Especially, whether the VOC content reaches the standard when the workpiece is directly welded without cleaning is a very important detection indicator, Obviously, oil-based lubricants and water-soluble stamping oils do not meet the standards. Driven by market demand and various changes, the stamping oil market is quietly undergoing significant changes. Many domestic and foreign manufacturers have launched oil-free (water-based) lubricants to enter the market on a large scale, attempting to replace water-soluble stamping oils that have been in use for many years.
