It has been said that there is a fine balance between art and science when it comes to metal forming lubrication. Subtle variations can occur during the forming process, die design and work piece metallurgy. All of these factors are critical and can greatly affect product performance. We are all aware of the benefits that come with selecting the right lubricant: it increases product life and ensures successful product output. However, it is also essential to understand that by practicing proper lube methods and applications for your business, you can optimize benefits in parts storage, cleaning, general housekeeping and even waste disposal costs and procedures. Lubrication provides an essential barrier between the roll dies and the product surface. It helps to preserve the life of the machine and reduce tool wear while allowing the work piece to move along faster and efficiently.
Whether you are using straight, water-soluble, synthetic and/or dry film oils, it is important to remember to only apply the lube where it is needed, when it is needed and solely in the amount it is required for. There are a number of application methods used but generally speaking, many manufacturers use more lube than is actually necessary. It is recommended that you should always decide first on what the optimum lube level for the job should be. From there, you can determine the best application system to maintain the desired lubricant levels. By applying precise lubricant levels to your process, you not only save in fluid costs but reduce clean-up on the factory floors, simplify part cleaning procedures, reduce paint blisters and lower environmental costs. Ideally, a system that incorporates low-volume and low-pressure technology aims to achieve optimum and efficient lubricant levels.
Always ensure that lube waste disposal meets all regulatory requirements especially if it enhances the roll forming process and reduces overall disposal costs. Remember, it is the manufacturer’s responsibility to ensure that proper waste removal guidelines are adhered to. Always remember the safety of your employees and the social responsibility of your organization. If your lube supplier says it is okay for lube to be dumped down the drain, remember the manufacturer bears the liability – buyer beware. ISO 14001 in your facility will also want to get involved with your company’s lube use, storage and disposal. Keep track of your lube procedures and avoid over application – proper monitoring will ensure all safety and quality requirements are being met. By understanding the environmental effects of your current lubricant and compatibility, you can audit your baseline environmental status and look to the many ways of outlining an improvement strategy when needed.
Managing your lubrication procedures, overall housekeeping, and keeping a regular log of lubricant levels are significant ways of cost reduction and overall savings for your organization. By doing so, you are helping to protect the environment for people, products and machinery. What are your company’s best practices regarding lube methodologies?
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