Cost Reduction Through Zero Maintenance Spraying Systems

7/28/2019 Cost Reduction Through Zero Maintenance Spraying Systems

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Hot Forging Die Lubrication by the use of

Zero Maintenance Spraying Systems Quick Comparison Chart:

Features

Zero

Maintenance

Spraying

System

Diaphragm Pump

with ElectricMotor

Conventional

Pressure Feed Tank

Conventional

Pressure feed

Tank withMotor

Ability to deliver all types of

die lubricants Yes Yes No Yes

Continuous automatic stirring /

agitation Yes Yes No Yes

Quick re-filling of die lubricant Yes Yes No NoLong life and low runningcosts Yes No Yes No

Zero unplanned downtime Yes No Yes No

Low maintenance Yes No Yes No

Low inventory costs Yes No Yes No

Economical Yes No Yes No

Abstract

In closed die forging, use of effective spraying system enables benefits like proper die

lubrication, maintenance of correct die temperature and prevention of over-heating or cooling

of die, prevention of wastage of die lubricant, ease of forging production and ease of

lubrication operation.

A number of forging companies are unable to use appropriate spraying systems due to

reasons like operator inconvenience, frequent maintenance downtime of motor and spraying

equipment, non-practical design of spraying system, high initial cost and recurring cost of

spraying equipment, inability to train workmen regarding correct usage of spraying system,

etc.

This presentation aims at reviewing the benefits of using spraying systems in hot forging die

lubrication. Evaluation of various types of die lubricant spraying systems available in the

market will be carried out. Shortcomings and benefits of most of the popular types of

spraying systems will be discussed. An innovative and proven zero maintenance spraying

system will be introduced.



Article

A range of environment friendly hot forging die lubricants are now available to the Indian

forging industry. Water soluble lubricants without graphite are becoming increasingly

popular for small to medium size forgings. For large, heavy forgings, graphite based

lubricants and oil based lubricants continue to be used.

Environment friendly die lubricants with and without graphite are found to be very effective

and economical when used with the appropriate spraying system. They facilitate zero

pollution and a clean working environment on the forge shop floor. Use of appropriate die

lubricant spraying system gathers much importance in the use of water based die lubricants.

A correct spraying system ensures effective die lubrication, reduced wastage of lubricant and

increased die life. Ease of operation of die lubricant spraying system determines its

acceptability by forging production personnel. Maintenance of the lubricant spraying systems

have posed a problem to many forging companies as unplanned downtime of spraying

system results in immediate use of furnace oil or such polluting and costly alternatives.

A large number of forging companies are switching over to zero maintenance spraying

systems manufactured by SPS to enable effective spraying of hot forging die lubricants on

their dies. Before we study the advantages of the zero maintenance spraying system, let us

have a quick look at the common forging die lubricant spraying systems available at present,

and their pros and cons:

1. Diaphragm pump type spraying system with motor: This spraying system is very

common in large forge shops. The powerful diaphragm pump is capable of spraying

up to 133 litres of paint per minute. It is able tospray very high viscosity paints. An even spray

is assured. Diaphragm pumps can be powered by

pneumatic air or electricity. Re-filling is very

easy as the open tank can be topped up with

lubricant as and when required. Continuous

stirring of lubricant is achieved by a separate

motor. This system is very effective where large

volumes of paint need to be sprayed

continuously. However, for the purpose of hot

forging die lubrication, the diaphragm pump type

spraying system is found to be over-equipped.The process of forging requires only a small

spray of lubricant on the forging dies between

each forging blow. Most forging dies do not

require more than 300 ml of lubricant per

minute. Forging lubricants are diluted in water in

high ratios such that the viscosity of lubricant is

maintained very low. Hence, the capacity of the



diaphragm pump is grossly underutilized if used for forging die lubrication.

Maintenance downtime problems usually occur after 12 to 18 months of use of the

diaphragm pump. In case of diaphragm pump downtime, the entire spraying system

can not be used in any way. Hence, use of diaphragm pump for the purpose of forging

die lubrication is a very inappropriate choice. Pros: Powerfully sprays high viscosity

paints. Refilling of lubricant in tank is very easy. Cons: Expensive. High running costas one additional motor and spares are required for stirring lubricant and diaphragm

pump used for spraying the lubricant. Unplanned downtime.

2. Conventional pressure feed tank with hand stirring: This simple spraying system

is functional and economical. It is powered by

pneumatic air to pressurize the tank and spray the

lubricant. Stirring is achieved by manually

rotating the handle of the stirrer. Re-filling is time

consuming and difficult as the entire lid of the

system needs to be unscrewed and dismantled for re-filling. In case of graphite based lubricants,

there is a tendency of graphite particles to settle at

the bottom of the tank if not stirred continuously.

The mixture quality of the lubricant will be

affected. Hence, there is room for human error if

the operator fails to stir the system manually at

frequent intervals. Pros: Functional. Simple.

Economical. Cons: Continuous stirring not possible and may affect lubricant

properties. Re-filling is time consuming and requires correct spanners to open the lid.

3. Pressure feed tank with motor: This is the upgraded version of the conventional

pressure feed tank. It is powered by pneumatic air to pressurize the tank and spray the

lubricant. A motor is affixed on the tank so that

continuous stirring of the forging die lubricant is

achieved. The rest of the functioning of this system is

the same as the conventional pressure feed tank.

Addition of the motor invites problems of motor

maintenance. However, even if the motor is not

functional, the system can still be used for spraying

lubricant. A risk of graphite particles settling at the

bottom of the tank and affecting the lubricant mix

will always prevail in such case. Pros: Functional.

Offers continuous stirring. Economical compared to

diaphragm pump type system. Cons: Re-filling is

time consuming and requires correct spanners to

open the lid. Additional motor adds to running costs. Unplanned motor downtime

may affect lubricant properties.



Considering the pros and cons of all the popular die lubricant spraying systems, SPS

has made a breakthrough in this area by designing a special spraying system. This has

proven to be better, easier to use and economical.

4. Zero maintenance spraying system:

This specially designed, most modern spraying system

has proven to be superior to other type of spraying

systems mentioned above. Special design enables a

number of beneficial features. The spraying system is

powered by pneumatic air to pressurize the tank and

spray the lubricant. Special internal mechanism

ensures that the same compressed air that is used to

pressurize the tank acts as an agitator to the lubricant.This ensures continuous mixing of the lubricant and

settling of graphite in the tank is not possible.

Additional motor is not required for stirring; hence

motor related problems are eliminated. Special design

enables quick re-filling of

die lubricant in less than a

minute, without the use of

any mechanical tools. This

system is capable of delivering die lubricant up to 3.3

litres per minute for spraying. This is found to be morethan sufficient for most forging die lubrication operations.

This capacity can be doubled by increasing the

compressed air supply up to 5 kgs./sq. cm. There are no

user-serviced parts in this system. Unplanned downtime of

spraying system is eliminated. No special inventory needs to be maintained for this

system. Safety valve, pressure gauge and air pressure regulator ensure safety and ease

of operation. Two forging presses can be serviced with one such spraying system by

making simple modifications. Tank capacities of 45, 100 and 200 litres are available.

Pros: Ideal spraying system for using all types of forging die lubricants. Continuous

stirring of lubricant is ensured at all times. Easy and quick re-filling of die lubricant is

assured. Zero maintenance as no user-serviced parts present. No inventory costs. Zerodowntime. Low running cost as no additional motor required. Economical. Cons:

Tank size of 400 litres is under development and will be available shortly.

Though all types of spraying systems are available with SPS, use of zero-maintenance

spraying systems for hot forging die lubrication is strongly advised. A quick

comparison chart of all spraying systems is provided below:



Quick Comparison Chart:

Features

Zero

Maintenance

SprayingSystem

Diaphragm Pump

with ElectricMotor

Conventional

Pressure Feed Tank

Conventional

Pressure feed

Tank withMotor

Ability to deliver all types of

die lubricants Yes Yes No Yes

Continuous automatic stirring /

agitation Yes Yes No Yes

Quick re-filling of die lubricant Yes Yes No No

Long life and low runningcosts Yes No Yes No

Zero unplanned downtime Yes No Yes No

Low maintenance Yes No Yes No

Low inventory costs Yes No Yes No

Economical Yes No Yes No

Double action sprayguns for effective die lubrication are available. Two side spray

and single side spray capable guns are commonly used for forging die lubrication.

Customized nozzles for special applications as per requirement can be developed.

Semi Automatic Spraying of Lubricant on Forging Dies through Fixed Nozzles and foot

operated pedal:

Specially developed spraying nozzles are fastened close to or around the forging die at an

angle such that the lubricant spray through the nozzles will land on the forging die. The spray

is controlled by a foot operated pedal. This technique is a convenient substitute for spraygunsin hot forging die lubrication and ensures complete safety. Additional workman solely for

purpose of spraying lubricant may not be necessary.



Use of zero maintenance spraying system manufactured by SPS have proven to enable the

following benefits:

1. No sticking of forgings. Smooth production.

2. Effective lubrication and cooling of die. This leads to increase in die life.

3. Quick re-filling of spraying system, in less than 1.5 minutes.

4. Zero maintenance of spraying system required.

5. Zero maintenance downtime of spraying system ensures continuous production.

6. Economical. Affordable and zero recurring cost of forging die lubricant spraying system.

For more details on Zero Maintenance Die Lubricant Spraying Systems, please contact:

STEEL PLANT SPECIALITIES211, Raikar Chambers, Govandi East, Mumbai-400088. India.

Tel.: 91 22 67978060 Fax : 91 22 25552459Skype: steelplantspecialities

E-mail: [email protected]: www.steelplantspecialities.com

Nozzles for semi automatic spray Foot operated pedal to control air and

lubricant release through nozzles.

Cost Reduction Through Zero Maintenance Spraying Systems

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