Journal Home > Volume 11 , Issue 9

The requirements for green and sustainable manufacturing mean that stamping lubricants must be continuously re-evaluated and re-designed. In this investigation, the tribological performance of four base oils with different chemical structures (paraffinic and naphthenic) and viscosities (2 and 20 cSt), as well as water, was evaluated for the stamping of steel sheets and compared with a non-lubricated contact. Most lubricants reduce the coefficient of friction and maintain a similar wear coefficient for steel sheets as in dry contacts. Low-viscosity (LV) naphthenic oil performs very like both high-viscosity (HV) oils. A surprising exception is the LV paraffinic oil, with several-times-higher friction and wear compared to dry contact. This is due to the excellent wetting-spreading and very low cohesion forces that enable oil to escape from extremely thin-film contacts because the viscosity is so low, leading to lubricant starvation. In contrast, HV oils provide a sufficiently thick lubricating film, while strong cohesive forces help in the film’s strength, lessening wear, and reducing friction. In thin-film lubrication with LV oils, such as when stamping, it is thus extremely important that the lubricant’s wetting behaviour and viscosity are sufficient to provide enough film in the contact and prevent starvation, thus ensuring lower friction, less wear, and a longer lifetime of the contact.


menu
Abstract
Full text
Outline
About this article

Base lubricants for green stamping: The effects of their structure and viscosity on tribological performance

Show Author's information Marko POLAJNARLucija ČOGAMitjan KALIN( )
Laboratory for Tribology and Interface Nanotechnology, Faculty of Mechanical Engineering, University of Ljubljana, Ljubljana 1000, Slovenia

Abstract

The requirements for green and sustainable manufacturing mean that stamping lubricants must be continuously re-evaluated and re-designed. In this investigation, the tribological performance of four base oils with different chemical structures (paraffinic and naphthenic) and viscosities (2 and 20 cSt), as well as water, was evaluated for the stamping of steel sheets and compared with a non-lubricated contact. Most lubricants reduce the coefficient of friction and maintain a similar wear coefficient for steel sheets as in dry contacts. Low-viscosity (LV) naphthenic oil performs very like both high-viscosity (HV) oils. A surprising exception is the LV paraffinic oil, with several-times-higher friction and wear compared to dry contact. This is due to the excellent wetting-spreading and very low cohesion forces that enable oil to escape from extremely thin-film contacts because the viscosity is so low, leading to lubricant starvation. In contrast, HV oils provide a sufficiently thick lubricating film, while strong cohesive forces help in the film’s strength, lessening wear, and reducing friction. In thin-film lubrication with LV oils, such as when stamping, it is thus extremely important that the lubricant’s wetting behaviour and viscosity are sufficient to provide enough film in the contact and prevent starvation, thus ensuring lower friction, less wear, and a longer lifetime of the contact.

Keywords: viscosity, water, wetting, stamping, paraffinic oil, naphthenic oil

References(45)

[1]
UNFCCC. Paris Agreement (2015) Information on https://unfccc.int/, 2021.
[2]
[3]
[4]
Kalpakjian S, Schmid S R. Manufacturing, Engineering and Technology. London (UK): Pearson Education, 2014.
[5]
Stephenson D A, Agapiou J S. Metal Cutting Theory and Practice. Florida (USA): CRC Press, Taylor and Francis Group, 2016.
DOI
[6]
Byers J P. Metalworking Fluids. Florida (USA): CRC Press, Taylor and Francis Group, 2006.
[7]
Kim H, Altan T, Yan Q. Evaluation of stamping lubricants in forming advanced high strength steel (AHSS) using deep drawing and ironing tests. J Mater Process Tech 209: 4122–4133 (2009)
[8]
Altan T. Forming trends in the automotive industry and their impact on lubrication. Tribol Lubr Technol 71(11): 46–48 (2015)
[9]
Mizuno T, Kataoka H. A study of the lubrication mechanisms in deep drawing. Bull JSME 23: 1016–23 (1980)
[10]
Voss B M, Pereira M P, Rolfe B F, Doolan M C. Using stamping punch force variation for the identification of changes in lubrication and wear mechanism. J Phys Conf Ser 896: 1–8 (2017)
[11]
Moghadam M. Limits of lubrication in severe stamping operations. Ph.D. Thesis. Kongens Lyngby (Denmark): Technical University of Denmark, 2019.
[12]
Jayadas N H, Prabhakaran Nair K, Ajithkumar G. Vegetable oils as base oils for industrial lubricants: Evaluation oxidative and low temperature properties using TGA, DTA and DSC. In Proceedings of the World Tribology Congress III, Washington DC, USA, 2005: 539–540.
[13]
Haglund B O and Enghag P. Characterization of lubricants used in the metalworking industry by thermoanalytical methods. Thermochim Acta 282–283: 493–499 (1996)
[14]
Canter N. Developing MWFs for lightweight metals. Tribol Lubr Technol 38: 46–57 (2014)
[15]
Ying T, Tolbert U, Zipkin D, Kunderewicz E. Nanotribology application in the coining industry, (I)-Turn off stamping oil sprayer during coining. Tribol Trans 56(3): 488–502 (2013)
[16]
Kalin M, Polajnar M. The correlation between the surface energy, the contact angle and the spreading parameter of DLC with lubricating oils. Tribol Int 66: 225–233 (2013)
[17]
Bosler P. New stamping lubricants meet new challenges. Met Form 47: 20–25 (2013)
[18]
Lauer D. Tribology: The key to proper lubricant selection. https://www.machinerylubrication.com/Read/1318/tribology-lubricant-selection, 2008.
[19]
Lovell M R, Deng Z. Characterization of interfacial friction in coted sheet steels: influence of stamping process parameters and wear mechanisms. Tribol Int 35: 85–95 (2002)
[20]
Kim H, Sung J H, Sivakumar R, Altan T. Evaluation of stamping lubricants using the deep drawing test. Int J of Mach Tool Manu 47: 2120–2132 (2007)
[21]
Chandrasekharan S, Palaniswamy H, Jain N, Ngaile G, Altan T. Evaluation of stamping lubricants at various temperature levels using the ironing test. Int J of Mach Tool Manu 45: 379–388 (2005)
[22]
Lovell M, Higgs C F, Deshmukh P, Mobley A. Increasing formability in sheet metal stamping operations using environmentally friendly lubricants. J Mater Process Tech 177: 87–90 (2006)
[23]
Rao K P, Xie C L. A comparative study on the performance of boric acid with several conventional lubricants in metal forming processes. Tribol Int 39: 663–668 (2006)
[24]
Bay N, Azushima A, Groche P, Ishibashi I, Merklein M, Morishita M, Nakamura T, Schmid S, Yoshida M. Environmentally benign tribo-systems for metal forming, Cirp Ann-Manuf Techn 59: 760–780 (2010)
[25]
Noder J, George R, Butcher C, Worswick M J. Friction characterization and application to warm forming of a high strength 7000-series aluminium sheet. J Mater Process Technol 293: 1-19 (2021)
[26]
Ortega Vega M R, Parisea K, Ramosa L B, Boffb U, Mattedic S, Schaefferb L, Malfattia C F. Protic ionic liquids used as metal-forming green lubricants for aluminum: Effect of anion chain length. Mater Res 20(3): 675–687 (2017)
[27]
Azushima A, Uda K, Yanagida A. Friction behavior of aluminum-coated 22MnB5 in hot stamping under dry and lubricated conditions. J Mater Process Tech 212(5): 1014–1021 (2012)
[28]
Aizawa T, Iwamura E, Itoh K. Nano-lamination in amorphous carbon for tailored coating in micro-dry stamping of AISI-304 stainless steel sheets. Surf Coat Tech 203(5–7): 794–798 (2008)
[29]
Aizawa T, Iwamura E, Itoh K. Development of nano-columnar carbon coating for dry micro-stamping. Surf Coat Tech 202(4–7): 1177–1181 (2007)
[30]
Yunata E E, Aizawa T, Tamaoki K, Kasugi M. Plasma polishing and finishing of CVD-diamond coated WC (Co) dies for dry stamping. Procedia Engineer 207: 2197–2202 (2017)
[31]
Aizawa T, Morita H. Dry progressive stamping of copper-alloy snaps by the plasma nitrided punches. Mater Sci Forum 920: 28–33 (2018)
[32]
Morita H, Aizawa T, Yoshida N, Kurozumi S. Dry transfer stamping by nano-laminated DLC-coated tool. In Proceedings of the 10th International Conference on Technology of Plasticity (ICTP), Aachen, Germany, 2011: 1103–1108.
[33]
Isoparaffinic Hydrocarbon – Isopar M solvent, Technical evaluation report. https://www.ams.usda.gov/sites/default/files/media/Isoparaffinic%20Hydrocarbon%20TR.pdf, 2008.
[34]
[35]
[36]
Purity 1020 base oil, Certificate of analysis. https://lubricants.petro-canada.com/en-gb/brand/purity-base-oils, 2019.
[37]
[38]
[39]
Hamrock B J, Dowson D. Isothermal elastohydrodynamic lubrication of point contacts. Part III. Fully flooded results. J Lubric Tech 99: 264–275 (1977)
[40]
Wu S, Brzozowski K J. Surface free energy and polarity of organic pigments. Journal Colloid Interf Sci 37(4): 686–690 (1971)
[41]
Fowkes F M. Attractive forces at interfaces. Indust Eng Chem 56(12): 40–52 (1964)
[42]
Carlson P. Surface engineering in sheet metal forming. Ph.D. Thesis. Uppsala (Sweden): Uppsala University, 2005.
[43]
Speight J G. The Chemistry and Technology of Petroleum. New York (USA): Marcel Dekker, Inc., 1999.
DOI
[44]
Velkavrh I, Kalin M. Comparison of the effects of the lubricant-molecule chain length and the viscosity on the friction and wear of diamond-like-carbon coatings and steel. Tribol Int 50: 57–65 (2012)
[45]
Kalin M, Polajnar M. The effect of wetting and surface energy on the friction and slip in oil-lubricated contacts. Tribol Lett 52: 185–194 (2013)
Publication history
Copyright
Acknowledgements
Rights and permissions

Publication history

Received: 12 January 2022
Revised: 06 April 2022
Accepted: 04 October 2022
Published: 25 March 2023
Issue date: September 2023

Copyright

© The author(s) 2022.

Acknowledgements

This work was supported by the company Hidria Rotomatika d.o.o and Slovenian Research Agency as part of research project No. L2-9244 and research core funding No. P2-0231.

Rights and permissions

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return