Abstract
The study discusses the subject of lubrication in the processes of hot die forging with the consideration of the durability of forging tools and instrumentation. It presents a literature research as well as the authors’ own investigations of the effect of the use of cooling and lubrication agents, the amount of the dosage as well as the direction of its application, and also the factors influencing the tribological conditions. The lubrication devices and systems currently applied in the industry have been analyzed as well. On this basis, making use of their knowledge and experience, the authors have developed and constructed a lubricating device. The elaborated system, implemented into the industrial process, makes it possible to select and ensure the optimal tribological conditions of the process by way of controlling the amount and frequency of the applied lubricant dosage. It can constitute an alternative for the manual method of lubricant application, which is dependent on the human factor, or the fully automated, yet expensive, lubrication systems. The obtained test results point to potential possibilities of a permanent introduction of the constructed device also into other forging processes, through its integration with a manipulator. The proposed solution ensures more stability and higher repeatability of the lubrication conditions as well as increases the efficiency of the production process, thus significantly reducing the unit costs of the production of forgings
Highlights
During the processes of die forging performed at elevated and high temperatures, the tools are subjected to very large, periodical thermal loads from 80 oC to 600 oC, as well as to mechanical loads reaching above 1200 MPa [39]
The study has presented an analysis of the effect of the cooling and lubrication agents, their dosage amount as well as time and direction of application, and the lubrication devices, on the wear of forging tools
The die forging processes performed at elevated temperatures are similar, each of them requires an individual approach
Summary
During the processes of die forging performed at elevated and high temperatures, the tools are subjected to very large, periodical thermal loads from 80 oC to 600 oC, as well as to mechanical loads reaching above 1200 MPa [39]. The lack of sufficient control over the lubrication process and the solve the analyzed problem An example of this can be an automated inappropriate adjustment of the nozzles at the beginning of the proc- method of lubrication on a crank-type press equipped with a transfer ess are the causes of a non-uniform wear (Fig.2b and Fig. 2c), which, of forgings, as is the case, for example, of the process of a constant in turn, causes a more intensified damage, shortening the tool opera- velocity joint body forging. A currently used, yet much cheaper than the expensive manipulators, and at the same time a highly automated lubrication system designed for hot die forging is a device developed by Jerko Company (Fig. 6) [19] This system has a special lubrication plate inserted between the upper and lower tools that applies a layer of grease. Despite the undeniable continuous technological development and the development of new technical solutions, the old, often unreliable and non-repetitive, lubrication devices are still used for most typical forging sets, which are supported
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