Modified Die Lubrication System for Forging Wheel and Axle Plant

Abstract

AbstractRailway wheels are manufactured by either forging or casting route. Forging process of wheel making involves upsetting, forging and rolling process followed by heat treatment and machining. During upsetting and forming operation metal flow depends on surface condition of dies and friction between dies and work piece. Absence of proper die lubrication results in poor die surface and uneven metal flow during forging. This leads to poor die life and higher rejections on account of dimensions. For improvement in die life and better dimensional accuracy, an automatic die lubrication system was designed, developed and installed at forging wheel and Axle Plant. Lubrication system was designed based on die wear pattern. Modified Lubrication system gets signal from the press after completion of upsetting, forming and piercing operation, which triggers lubrication process for top and bottom dies. Initially, scales are cleaned from bottom dies using compressed air. After that lubrication of top and bottom dies of upsetting, forming and piercing press takes place. Water-based graphite is used in 1:10 ratio for lubrication. Spray time for dies varies as per condition and requirement of dies and type of wheel being manufactured. Automatic lubricating system works in both auto and manual mode and has interface with other press equipments. Automatic lubrication system has resulted in elimination of sticker formation between work piece and dies during forming process. Additionally surface quality of dies has improved and rejection on account of forging at machining stage has reduced by around 2%.