FAQs

Choosing the right lubricant for metal stamping applications is critical to ensure efficient production, high-quality output, and the longevity of equipment. The right lubricant not only reduces friction and wear but also enhances the stamping process by preventing issues like metal deformation, corrosion, or premature tool failure. To make the best choice, manufacturers need to consider several factors, including material compatibility, process requirements, performance testing, and economic impact. 

Assessing Material Compatibility and Requirements

One of the first steps in selecting the best lubricant for metal stamping is to assess the material being stamped. Different metals have unique properties that require specific lubricants to achieve optimal results. For example, non-ferrous metals like aluminum and copper are softer and more prone to surface damage, requiring a lubricant that offers easy cleanup and minimal residue. In contrast, ferrous metals such as steel and iron often require heavier-duty lubricants to handle the higher pressures and temperatures involved in stamping. In addition to the type of metal, manufacturers must also consider the thickness of the material. Thicker metals typically require lubricants with higher viscosity to ensure consistent protection

throughout the stamping process. On the other hand, thinner metals may benefit from lighter lubricants that allow for smoother, more controlled movement of the die. Another important aspect to evaluate is the end use of the stamped product. For instance, components that will be painted, coated, or welded after stamping require lubricants that are easy to remove without leaving residues that could interfere with downstream processes. Water-soluble lubricants are often preferred in such cases due to their easy washability.

Finally, the specific type of stamping process, whether it’s deep drawing, piercing, or blanking, will influence the choice of lubricant. Different processes generate varying levels of heat and stress on the material, so it’s important to choose a lubricant that can withstand these conditions while maintaining its protective properties.

Performance Testing and Economic Considerations

Once material compatibility and process requirements are understood, it’s crucial to conduct performance testing to ensure that the selected lubricant meets the demands of the stamping process. Manufacturers typically evaluate lubricants for their ability to reduce friction, minimize wear, and cool the material and tooling. This often involves testing lubricants under real-world conditions to determine how well they perform in terms of tool life, part quality, and overall operational efficiency.

During performance testing, it’s essential to monitor how the lubricant affects the finish of the stamped part. Some lubricants may leave unwanted marks or discoloration, particularly on softer metals. This is particularly important in industries like automotive or appliance manufacturing, where surface aesthetics are critical. Testing can help identify lubricants that strike the right balance between protection and surface quality. Economic considerations also play a major role in selecting the best lubricant. While some high-performance lubricants may offer superior protection and efficiency, their cost may not be justifiable for all applications. Manufacturers should calculate the total cost of ownership, taking into account factors such as the lubricant’s impact on tool wear, maintenance requirements, and

the need for post-stamping cleaning.

Additionally, certain lubricants can be recycled or reused, which can lead to cost savings in high-volume operations. For instance, some water-soluble lubricants can be filtered and reused for multiple cycles, reducing waste and the need for constant replenishment. This is especially valuable in industries where reducing material waste and operational costs are critical to maintaining profitability.

Conclusion

Selecting the best lubricant for metal stamping applications requires a careful analysis of material compatibility, stamping process requirements, performance testing, and economic considerations. By choosing a lubricant that matches the specific needs of the metal and process, manufacturers can improve efficiency, reduce tool wear, and produce high-quality stamped parts. Performance testing and a thorough cost-benefit analysis are crucial steps to ensure the chosen lubricant not only delivers the desired performance but also contributes to long-term savings and sustainability. Ultimately, selecting the right lubricant is key to optimizing

the metal stamping process and achieving operational success.

Metal stamping, a process used in manufacturing to shape and cut metal sheets, involves significant friction and heat between the die and the metal. To reduce wear and tear on equipment, improve product quality, and enhance operational efficiency, lubricants are applied during the metal stamping process. Choosing the right lubricant depends on the specific application, materials being worked on, and the final product requirements. This article explores two common types of lubricants used in metal stamping: water-soluble lubricants and oil-based lubricants.

Water-Soluble Lubricants

Water-soluble lubricants, also known as emulsifiable lubricants, are widely used in metal stamping due to their versatility, eco-friendliness, and ability to be easily cleaned off the metal surface after stamping. These lubricants are made by blending oil with water and chemical additives to form an emulsion. The water in the solution helps cool the metal and die, while the oil provides lubrication to reduce friction and wear.

Benefits of Water-Soluble Lubricants

One of the biggest advantages of water-soluble lubricants is the water component utilized to extend the lubricant and reduce residue on press, floor, and parts. In metal stamping, excessive heat and pressure can damage both the metal and the stamping equipment. The water component effectively dissipates heat, maintaining optimal operating temperatures and extending tool life. The chemical component activates when stamping to reduce metal to metal contact. Another key benefit is their ease of removal. Since these lubricants are water-based, they can

be easily washed off the metal surface after stamping. This reduces the need for harsh cleaning solvents and helps maintain the integrity of the metal for subsequent processing stages, such as painting or coating. Water-soluble lubricants are also considered environmentally friendly. They contain fewer volatile organic compounds (VOCs) compared to oil-based alternatives, reducing their environmental impact and making them a popular choice in industries aiming to adhere to strictenvironmental regulations.

Common Applications of Water-Soluble Lubricants

Water-soluble lubricants are often used in applications where cleanliness is crucial, such as in the automotive and appliance industries. They are ideal for use on non-ferrous metals like aluminum and copper, which require a lubricant that can be easily removed without leaving any residue that might interfere with subsequent processes.

Oil-Based Lubricants

Oil-based lubricants, as the name suggests, are primarily composed of petroleum or synthetic oils. These lubricants offer excellent lubrication properties and are known for their ability to form a durable, protective barrier between the metal and the die. Unlike water-soluble lubricants, oil-based lubricants do not contain water and are generally more suited for heavy-duty stamping operations.

Benefits of Oil-Based Lubricants

Oil-based lubricants provide superior lubrication, making them ideal for applications that involve high-pressure or high-impact stamping. The oil creates a strong film on the metal surface, significantly reducing friction and wear on both the metal and the stamping equipment. This can result in longer tool life, reduced maintenance costs, and improved product quality. Additionally, oil-based lubricants excel in preventing corrosion. Many of these lubricants contain anti-corrosion additives that protect the metal during the stamping process and even afterward, especially during storage or transport. This makes them a preferred choice in industries where rust prevention is a priority.

Common Applications of Oil-Based Lubricants

Oil-based lubricants are typically used in heavy-duty metal stamping processes, such as in the production of steel parts for the automotive, aerospace, and construction industries. They are particularly effective when stamping ferrous metals like steel and iron, which require a more robust lubricant to withstand the higher pressures and temperatures involved.

Conclusion

The choice of lubricant in metal stamping plays a critical role in ensuring the efficiency, quality, and longevity of both the tooling and the final product. Water-soluble lubricants are favored for their cooling properties, ease of removal, and environmental benefits, while oil-based lubricants provide superior lubrication and corrosion protection, making them ideal for more demanding stamping applications. The right lubricant for your operation will depend on factors such as the

material being stamped, the complexity of the process, and specific industry requirements.

Nanotechnology is technology that deals with dimensions and tolerances  of less than 100 nanometers, especially the manipulation of individual  atoms and molecules.  A lubricant that is developed to activate at the  molecular level is able to have more complete coverage and remain  engaged between the tool and material where others may be squeegeed out. Nanotechnology significantly decreases heat and provides a  thorough wetting of the metal for full coverage and interface to the  tool and part surface. Due to the low viscosity of nanotechnology formulas, manufacturers are able to hold tighter tolerances without any  hydraulic push back. This helps preserve proper part thickness and enables greater forming accuracy, while reducing splits.

The true cost of a lubricant involves dilution ration and takes into consideration the impact of that product on many aspects of production. Poorly performing lubricants can add costs, such as: shortened die coating life, shortened tool life, additional prep, production down time for maintenance and repair, personnel costs,  shorter sump life, defective parts, high scrap rate, etc. We seek to provide products that are cost efficient across your entire operation.

Price-per-Gallon, which typically  refers to the retail price of a product, does not necessarily reflect  the cost of a product when in production. Many products are sold in a  concentrate that requires diluting with water before use.  Price-at-the-Machine is a more accurate measurement of the cost of a  product in use than the Price-per-Gallon purchase price.

For  example, one gallon of concentrate that sells for $20.00/gallon but is  diluted 8:1 (8 parts water to 1 part concentrate) has a  Price-at-the-Machine of $2.23 ($20.00 divided by 9 parts). One gallon of  a product that sells for $10.00/gallon but is diluted 2:1 (2 parts  water to 1 part product) has a Price-at-the-Machine of $3.34 ($10.00  divided by 3 parts).

Traditional stamping/drawing lubricants rely on mineral oils, lubricity  additives, and high molecular weight polymers to reduce wear and prevent  metal to metal contact in stamping metal parts. These conventional  mechanisms resist metal-to-metal contact utilizing hydrodynamic and  boundary film interfaces. Under extreme pressure, conventional chemistry  breaks down causing friction, heat and wear. The higher temperatures  generated by friction can cause tool coatings to fail prematurely.  Galling may also occur when material "cold welds" to the tool causing  press downtime, die change, or tool maintenance and/or replacement.  Nanotechnology compounds allow materials to activate at the nano level  when these extremes are reached to extend the protection at the forming  interface.

Increasing the profitability is directly related to improving  efficiencies. If any area of the production process can be made more  efficient, it will positively impact calculated profitability of a part.  Typically, manufacturers calculate 10-12% of the “piece price” for  tooling, maintenance and repair costs. That percentage can be reduced by  improved efficiencies (such as, lengthening die coating and tool life, less frequent re-coating and polishing, decreased down time, lower scrap  rate, etc.) in the production process.

Not necessarily. It is important to note that each coolant has its own unique concentration readings. One coolant may have a refractometer  reading of 9.2°Bx at 10% concentration (10:1) while another coolant may  read 3.3°Bx at the same concentration. Water-soluble oils typically have  the highest refractometer scales and synthetic coolants typically have  the lowest. Make sure to check with your coolant manufacturer for the  correct scale for your coolant.