A stamping company that produces steel and aluminum stampings, extrusions and welded assembles had problems with tooling life on a set of closed-end extrusions. The extrusions are fabricated from cold-rolled steel and stamped to extrude a ½" long ferrule with a ⅝" inside diameter on a 600-ton mechanical press at 20 strokes a minute. These extrusions carry tight tolerances and create tremendous pressure inside the die because they do not pierce through the other side.
With its previous lubricant, the company was only getting 5,000-10,000 hits out of the punches before galling occurred and the titanium nitride coatings in the die wore off. Operators were continually changing the threeout dies to have them stripped and reworked. The company performed two die change-outs a day and had to have 30 punch sets on hand at all times. With three punches running these extrusions, there was excessive downtime.
The company needed a barrier lubricant to protect against wear and the extreme pressure that built up in the dies. After switching to Metal Mates HDP-HSS wateremulsified lubricant, the company saw their hit count before punch changes increase from 5,000-10,000 to over 30,000.
Using HDP-HSS allowed the company to increase their uptime tremendously and, unlike other barrier lubricants, Metal Mates HDP-HSS is weld-friendly and doesn’t need to be washed off before welding. The company saves more than $800 per 35,000 part run by switching to HDP-HSS simply by extending the punch life.
The company is able to simplify production and save even more because they order their HDP-HSS premixed so they don’t have to rely on operators to mix the lubricant themselves, preventing over-use.
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"Operators often believe ‘More is Better’ when it comes to lubricant and will end up using way more than they need. (Metal Mates) worked extensively with the operators and trained them on applicator nozzles placements to get the proper amount of lubricant where and when needed."