Page 27 - MetalForming June 2013

more readily available. These products contain levels of microwax that prevent oil migration on coils or blanks. As a result, the coating is uniformly light and coils do not seep oil. These high-lubric- ity coatings usually do not require lubri- cant application at the press. In more difficult operations, compatible oils known as spot lubricants can be applied strategically for ancillary protection.
North American stamping compa- nies have traditionally applied lubri- cant at the press. Here, new light-vis- cosity oils are available that are approved by most OEMs. These prod- ucts provide high-performance lubric- ity and can be applied through tradi- tional methods. While disposal can be more expensive than with previously developed lubricants, typically the vol- ume of disposed lubricant is substan- tially reduced when compared to the use of water-miscible lubricants.
The characteristic film strength and tenacity of neat oils usually requires less-frequent and lower-volume appli- cation, and many formulations are designed to not drip from parts or presses. They eliminate any potential reactions with hard water and will not develop microbial issues. The driving feature is their ability to protect bare and zinc-coated steel from corrosion.
Tight Nestling, and Other Ways to Prevent Puddling
Historically, North American stam- pers use water-miscible lubricants. Here, costs can be substantially reduced by diluting these products with water. Whether the oil is derived from petroleum or plants, many of these emulsions provide substantial anti-corrosion protection. This char- acteristic can be increased by stack- ing parts in a manner that avoids lubri- cant puddling, or tight nestling.
Better yet, work to optimize appli- cation to avoid excessive residue. This strategy proves most important when working with synthetic lubricants. Stampers must avoid saturating parts when using these water-based prod- ucts. Galvanealled steel is most prone to corrosion in this condition, but even
galvanized and bare steel can corrode when overly wetted with synthetics.
Some synthetic lubricants have reduced alkalinity, and may be designed with poor wetting character- istics so that lubricant beads off the part. These conditions reduce the expo- sure to conductive films and improve compatibility with zinc-coated steel. However, alkalinity in synthetic lubri- cants provides the primary anti-cor-
rosion properties on ferrous metal. Also, poor wetting characteristics may require excessive reapplication or may lack the film presence required for severe stampings.
A select few synthetic lubricants provide synthetic vapor barriers or may provide controlled passivation of zinc. These products reduce the risk of cor- rosion, but none outperform neat oils or even some emulsions. MF
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