Lubrication is an important factor in cold forging because it reduces the friction between the metal and the die, preventing the wear of both. It also plays a vital role in reducing heat generated by forging processes. Furthermore, lubricating agents may act as a separating medium, preventing parts from sticking to each other and resulting in better-quality parts.
Various types of lubricants are used in cold forging processes, including oil-based, water-based, and synthetic oils. In addition to lubricating the surfaces of dies and parts to help reduce friction, some lubricants also contain anti-corrosion properties which can help increase tool life.
The choice of a suitable lubricant depends on factors such as the type of material being forged, forging temperatures, and the size of the part. In general, oil-based lubricants are used for high-temperature cold forging processes while water-based lubricants are more suitable for lower-temperature operations. It is important to select a suitable lubricant that can work properly within the specified temperature range and provide good lubrication to reduce friction and wear.
Key benefits of good lubrication in cold forging include:
Improved tool life:
Lubrication helps to reduce friction and wear between the tooling and the workpiece, which can prolong the life of the tooling and reduce the need for costly tool replacements. Also, by eliminating the risk of metal-on-metal contact, lubricants can reduce heat build-up and help to prevent the workpiece from seizing or sticking to the tooling.
Improved part quality:
High pressure and friction during cold forging can cause metal fatigue and burrs on the finished product, reducing its strength and durability. Lubrication helps reduce pressure and friction, ensuring that the finished part is strong and free from imperfections.
Improved productivity:
Lubrication can help to improve the accuracy and speed of cold forging processes, reducing cycle times. With a well-balanced lubricant, tools can move faster and more accurately for a higher-quality output. It also helps to reduce downtime and the cost of production.
Improved safety:
Using a good lubricant can help keep the environment free from hazardous chemicals, fumes, and sparks created when tools come into contact with each other. This not only protects workers in the facility but also helps to protect surrounding equipment and systems. Additionally, lubricants can reduce the risk of injury when handling tools and workpieces.
Reduced energy consumption:
Good lubrication helps reduce friction and heat generation during the forging process, which can lower the machine’s energy consumption and reduce costs.
Overall, proper lubrication is essential in cold forging processes for reducing friction, wear and heat generated during operations and improving part quality and safety. It also helps to extend tool life and increase productivity while reducing energy consumption and costs. Careful selection of a suitable lubricant is required to ensure optimal results.
At Syscon Wires, we manufacture cold heading quality wire using a cold forging process and top-grade lubricants to ensure the best quality parts and lifelong performance. Contact us today for more information!