Cost control and green environmental protection in stamping processes

Thread Content

World technology is changing, lubrication techniques are changing, environmental protection and energy conservation are changing, and the laws governing the use of chemicals are also changing. Therefore, the principles of metal forming lubrication that have been in use for many years have also changed as a result. Driven by market demand and various changes, the stamping lubricant market is undergoing significant transformations. Water-based lubricants (also known as “water-soluble stamping oils, volatile stamping oils, or sheet metal stamping oils”) offered by numerous manufacturers at home and abroad are beginning to enter the market on a large scale, in an attempt to replace the mineral lubricants that have been in use for many years. What is a true water-based lubricant? - Safe and environmentally friendly – colorless, non-flammable, free of oil as well as any solvents – features a thermosensitive, reverse-melting chemical formula – thin in consistency yet more effective than thicker oil films – truly soluble in water. In response to the concerns of many netizens and users, and based on years of market research and practical experience, I will explain the differences between water-based lubricants (also known as oil-free lubricants) and water-soluble stamping oils from three key aspects, to help everyone distinguish between them. As follows: I. Basic synthesis process for water-soluble stamping oil: This is what is commonly referred to as an emulsion, which is synthesized using mineral oil as the base material, along with emulsifiers, water, and rust inhibitors (when oil is dispersed in water, it is called an oil-in-water type; otherwise, it is an water-in-oil type). Additionally, depending on the difficulty of shaping the workpiece, the proportion of mineral oil used varies for different types of products. Given that the main feature underlying the development of water-soluble stamping oils is their ease of cleaning or the ability to function without the need for cleaning, large amounts of volatile substances must be added in order to reduce residues in the products. Oil-free (water-based) lubricants: These are formulated using water as the base, with the addition of high-molecular weight anti-epoxy polymers, thermosensitive reaction polymers, and rust-inhibiting agents; they must not contain any oils or volatile toxic substances. According to current market research, the only company in the world that is truly capable of developing and producing oil-free lubricants is the American company IRMCO. II. Technical performance of water-soluble stamping oil: 1. The solution tends to separate into layers during storage or use ； 2. It can meet the forming or drawing requirements for ordinary workpieces, but it is unable to meet the requirements for heavy-duty, high-strength steels, or deep drawing applications ； Prolonged use has a significant impact on the wear of the mold ； 3. Since it is an emulsion, the volume of the droplets is relatively large, resulting in a higher consumption amount when used for spraying ； 4. A large amount of chemicals such as degreasers are required in the cleaning process, and the cleaning water temperature should generally be maintained between 50-60 degrees℃ ； 5. Due to the presence of oil, if it is not cleaned properly, it significantly increases the rate of rework required for painting. Oil-free (water-based) lubricants: 1. Using water as the base material, no precipitation or stratification occurs upon long-term storage ； 2. Since it contains no oily components, it can be thoroughly cleaned using plain water at a temperature of 20–40°C during the cleaning process, without the need to add any degreasers or related chemicals ； 3. During the stamping process, due to the thermosensitive remelting property of polymers, steam can be generated rapidly to carry away heat, thereby reducing the temperature of the mold. Additionally, a tough protective lubricating film is formed, which improves the fluidity of the metal and extends the lifespan of the mold ； Therefore, it is very helpful for increasing the number of strokes and protecting the mold ； 4. The droplets are small in size, allowing the nozzle to be made even smaller; the spraying area for the same amount of material is much larger compared to oil-based products ； 5. According to the available information, the oil-free (water-based) lubricants produced by the American company IRMCO can effectively solve the problems associated with the forming and drawing of high-strength steel and thick plates ； III. Safety-oriented water-soluble stamping oils: These products generally have a short shelf life; they tend to crack during use and emit an unpleasant odor, posing a significant impact on the production environment ； At the same time, the addition of chemicals such as solvents and emulsifiers to the product can cause severe damage to the skin and respiratory tract ； More importantly, some substances in the products are carcinogenic, and strict treatment is required before they are released. Currently, the test reports provided for such products are generally only those regarding basic technical performance, and there are yet no test reports on toxicity or similar aspects available for users to refer to or use. Oil-free (water-based) lubricants: These products have a very long shelf life. Since water is used as the base material and no toxic chemicals are added, they can come into direct contact with the skin without causing harm to human organs such as the respiratory system over time. Especially when workpieces are used for welding without any need for cleaning, it is crucial to ensure that the VOC levels meet the specified standards; obviously, oil-based lubricants and water-soluble stamping oils do not meet these standards. However, according to the information available, the oil-free lubricants produced by the American company IRMCO not only have VOC levels in welding fumes that meet the standards set by the U.S. Department of Labor, but they are also the only lubricant manufacturer in the world to have established a laboratory for testing low-toxicity substances. At the same time, testing in accordance with the EC50 aquatic toxicity test method adopted by the U.S. Environmental Protection Agency, which is also the most advanced method available internationally, ensures safety; in other words, this product fully meets the standards for direct discharge.