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Synthetic Stamping Lubricant

Metal Stamping (metalworking) is the process of placing flat sheet metal in either blank or coil form into a Stamping press where a tool and Die (manufacturing) surface forms the metal into a net shape. That Tribology process generates friction which requires the use of a Lubricant to protect the tool and die surface from scratching or galling. The lubricant also protects the sheet metal and finished part from the same surface abrasion as well as facilitate elastic material flow preventing rips, tears or wrinkles. There are a variety of lubricants available for this task. They include plant and mineral oil based, animal fat or lard based, graphite based, soap and acrylic based dry films. The newest technology in the industry is polymer based synthetic lubricants also known as oil-free lubricants or non-oil lubricants. The term "Water-Based" lubricant refers to the larger category that also includes more traditional oil and fat based compounds.

History and Development

The first synthetic stamping product used for heavy stamping was invented in 1982 by Mr. Art Dampts while employed as Director of Research at Evanston Illinois based IRMCO®www.irmco.com. Mr. Dampts was also the first to coin the term “non-oil fluid” as a distinction from other types of legacy lubricants. IRMCO Non-Oil Fluids® were unique for the time. While in the early 1980’s synthetics were not new to the cutting fluid industry, stamping lubricants were typically a heavy oil or a pigmented loose fatty emulsion. The lubricant choices for metal stamping companies had gone relatively unchanged since the 1930’s when Henry Ford approached George Pillsbury, founder of Pillsbury Chemical and Oil to formulate a stamping/drawing compound for his River Rouge Plant. The Pillsbury Drawco product was a white, pigmented paste product formulated with calcium and animal fat. This kind of product chemistry became a standard for the industry and is still used in many automotive plants today. Mr. Dampts and IRMCO were the first to use polymer based ingredients.

Synthetic Stamping Lubricants should not be confused with Synthetic Synthetic oil -- chemically modified petroleum distillates commonly used as motor oils and other maintenance oils. Synthetic Stamping Lubricants are water-based solutions containing anywhere from 35% to 80% water in their concentrate form. Synthetic Stamping Lubricants are typically a complicated blend of poly glycol and/or ester based polymers. Some pseudo synthetics or “look a likes” are soap-based products utilizing plant oils or other fatty materials. The term “Synthetic” has become overly broad in recent years creating some market confusion.

Mr Dampts impetus to invent the synthetic stamping lubricant category was driven by the remnants of the 1973 Arab Oil Embargo 1973 oil crisis and the very real 1979 energy crisis. Domestic oil was in short supply and prices were rising. Art Dampts’ innovative use of polymers made water behave more like oil in the metal stamping process. His synthetics were more viscous and displayed an ability to stay in place in some of the most severe metal stamping and drawing operations. Using water instead of oil as the base of the product created less dependence on foreign oil supplies and better price and supply stability.

Industry Adoption

One of the first industries to take advantage of and embrace the new synthetics were lawn and garden manufacturers such as Ariens, John Deere Tractor, Murray (bicycles) in Tennessss and AYP (now Husqvarna AB). Companies making lawn mower decks and tractor fenders struggled with using heavy oil and its effect on downstream costs such as parts cleaning, welding and paint quality. Automotive manufacturers took a little longer to consider the new technology. Nissan Motor Company was the first OEM to accept a synthetic when they approved IRMCO Non-Oil Fluids® 146-000 in 1989. North American-based OEMs did not approve a synthetic until Ford Motor Company approved one in 2000. Most European OEM Automakers have not made the decision to approve oil free or synthetic stamping lubricants.

Environmental Benefits

After IRMCO’s first synthetic introduction in 1982, the company was alone in the market for over 5 years. As with anything new, the metal stamping industry was slow to change. Oil or animal fat products still dominated the market for many years until synthetics were able to prove themselves in the marketplace. It was soon discovered that the right synthetic formulation was more Environmentally friendly when or if it reached the environment, essentially starting the “green” movement in metal stamping plants. When users were able to remove oil from their operations by using a synthetic, they were able to take advantage of a cleaner plant, easier product recycling or disposal and less energy and chemicals needed to clean and prepare metal parts for e-coating and painting. Oil and animal fat formulations also have a much more toxic fish kill or LC50 rating compared to properly formulated synthetics.

Continued Development

With the introduction of Advanced High Strength Steel (AHSS) also referred to as Ultra-high-strength steel (UHSS) the frictional demand on metal stamping and drawing dies has driven the need for a more modern water-based lubricants. The AHSS properties that exhibit themselves in the metalforming process are the same as those seen when the metal is used in a vehicle and that vehicle crashes. AHSS is engineered to be lighter and stronger, however when it is “worked” in a tool and die, the metal work-hardens (Work hardening) and requires more energy to form into a net shape. The increase in work hardening and required forming force/energy combine to create a more demanding temperature range and higher demand for lubrication. IRMCO research engineers discovered that proprietary polymer synthetics are heat activated and work better the harder they are pushed. With the increase in frictional temperatures, traditional oil and fat based formulations will fail sooner.

References

• Don Hixon, 1984, December, "Alternative Lubricant Offers Advantages for Stamping", Precision Metal, page 13
• William C. Jeffery, 1985, November, "Non-Oil Drawing Compounds Make Dollars and Sense", Metal Stamping, pages 16-17
• Phillip Hood, 1986, Spring, "Environmental Compliance - A Lawn and Garden Manufacturers' Approach to Stamping Lubricants and Environmental Change", Stamping Quarterly, Pages 24-25
• Pioneer Press, April 27, 1989, Marilyn Claessens, "At 75, IRMCO still a pioneer - Lubricants go down the drain by design", Evanston, IL, page 33
• Bradley Jeffery, 1991, August, "Environmental Solutions for Metal Stamping", MAN, pages 31-32
• Robin P. Bergstrom, 1991, November, "Stamping Made Clean(er)", Production Magazine, pages 54-55
• 1991, February, "Lubricants and Environment Mix", Manufacturing Engineering, pages 52-59
• Brian S. Cook, 1992, January 6, "Appropriate Technology", Industry week, pages 51-52, 58.
• James R. Rozynek, 1995, Winter, "Case Study: Converting to Water-Based Metal Stamping Lubricants", Stamping Quarterly, pages 31-33
• Philip Ward, 1996, July/August, "Water-Based Stamping Lubricant Washes Away Oil-Based Lube Problems", Forming & Fabricating, pages 52-56
• Matt Bailey, UK, 1997, May, "Non-Oil Lubricants Offer Solvent Solution", Sheet Metal Industries, pages 14-15
• Chris Wren, UK, 1999, June, "One Out - Oil Out" Sheet Metal Industries, pages 21-22
• Brad Jeffery, 2003, April, "The Bottom Line - Getting your N-Values Worth", Modern Metals, page 76
• Brad F. Kuvin, 2007, February, "Forming Advanced High Strength Steel Leaves No-Room for Error", MetalForming, pages 32-35
• Brad F. Kuvin, 2007, May, "Dana's Giant Lube Leap of Faith", MetalForming, pages 32-33
• Hyunok Kim PhD, 2008, March "Evaluation of Deep Drawing Performance of Stamping Lubricants with Dual Phase (DP) 590 GA", Part II in III part series, The Center for Precision forming (CPF), The Ohio State University, pages 1-5
• Brad F Kuvin, January, 2009, "Deep-Draw Automation returns remarkable results", MetalForming, pages 14-15