Share content on LinkedIn Share content on YouTube

Lubrication Innovation Abates Waste

July 29, 2024
0
Comments

Heavy-gauge stamping specialist Pentaflex overhauls its die-lubrication strategy, first by reducing the number of lubricants it uses among its numerous high-tonnage presses from six formulations down to two, and then by installing a central, proportional mixing system plumbed to 12 presses.

For the last 2-3 yr., the production team at heavy-metal stamper Pentaflex, Springfield, OH, has worked diligently to reduce the number of die-lubricant formulations it uses throughout its sprawling facility, from six formulations down to just two. More recently, the firm has taken the next step in fine-tuning its lubrication strategy, by installing, early in 2024, a proportional mixing system and then plumbing the system to 12 presses—a combination of high-tonnage mechanical and hydraulic models. The mixing system, a Pro Mix double-recirculation setup engineered and manufactured by Industrial Innovations, has brought a new level of dilution control and automated delivery to each press, which already has paid palpable benefits to the firm. 

Industrial Innovations Pro Mix double-recirculation systemSays Pentaflex president Ross McGregor:

“Once we successfully narrowed our lubricant use to two formulations, working in partnership with Fuchs Lubricants, the next step became reengineering our process for mixing and delivering lubricant to the presses. Since installing the Pro Mix setup, we’ve documented a 25% reduction in lube consumption. And, it’s become apparent that the plant is much cleaner than before. Operators no longer need to mix their own lube and haul buckets back and forth to fill reservoirs, and there’s no longer partially full buckets sitting around. We’ve eliminated all of those sources of waste.”

Stamping High-Strength Steels, Deep-Drawing Stainless

12 presses at PentaflexMuch of the stamping performed at Pentaflex fulfills orders from customers in the medium- and heavy-duty truck industry, supplying axle and brake components and subassemblies. The firm’s presses—mechanicals to 1600-ton capacity, including two servomechanical models (330- and 700-ton), and hydraulics to 2300-ton capacity—form high-strength steels ¼ in. and thicker, and deep-draw stainless steels. 

“One of our most severe operations,” shares McGregor, “requires our 1600-ton hydraulic press to perform a 10-in. draw of a highly engineered stainless-steel blank to form an exhaust-system component (a catalytic converter housing for class 8 trucks). It requires a four-station operation under one ram, in a transfer die, and lubrication obviously plays a critical role in that operation, as it does in nearly every tool we run.”

The lubricant here: Fuchs’ Renoform OS 7250, a heavy-duty emulsifiable drawing and stamping compound intended, according to Fuchs, for severe drawing, stamping and blanking operations. Pentaflex typically mixes the lube to a 20% concentration with water. It’s designed to resist microbial growth, so it reportedly provides long sump life in recirculating systems. 

Pentaflex’s Pro Mix mixes the OS 7250 lubricant, as well as Fuchs’ Renoform OS 7806, a chlorine-free water-soluble drawing and stamping lubricant intended for severe drawing and stamping. Fuchs notes that the formulation often finds use to replace highly chlorinated products, helping to eliminate post-process cleaning and special wastewater-disposal requirements. And, it’s designed to maintain a stable pH and resist microbial growth, making it a candidate for recirculation.

“Fuchs played a vital role in helping us analyze the parts we run and the materials stamped,” says McGregor, “and we tested several formulations until we found two that would handle the vast majority of our projects. We still have a handful of unique jobs where we have to mix a special blend of lubricant to get the jobs to run, but that’s the exception, not the rule.”

Top-of-the-Line Lube-Mixing Control

The new distribution system then accommodates the two lubricants Pentaflex settled on; lubricant selection is included in each part programmed into the press controls. The lube concentrations have remained the same since installing the new distribution and mixing system, McGregor says, but operators do pay close attention to the lubricant pumped to the presses located farthest from the mixing station—its hydraulic models. 

deep drawn catalytic converter housingTaking over operational control of the Pro Mix system is Industrial Innovations’ top-of-the-line CPM-5 automatic lubricant-controls package. It provides Pentaflex with digital control of dilution, and ultrasonic tank-level monitoring with high- and low-level alarms. Also included are digital pressure sensors with high- and low-pressure switch monitoring, and the ability to monitor the amount of water and lube consumed in gal/min.

The Pro Mix also monitors pump flow of water and lubricant to determine the exact mixture ratio for each batch.  

“Then, at the far end of the distribution plumbing, at our hydraulic presses, we keep an extra-close eye on dilution and ensure that the spray nozzles remain clean and attain sufficient pressure,” McGregor shares. “To monitor dilution, the operator takes a refractometer down to the press at the start of a run or when we’re changing lubes and confirms the dilution. This takes on added importance at the hydraulic presses because they’re typically performing the most severe draws.”

Recirculation Minimizes Bacteria Growth

The double-circulation system requires minimal maintenance, and infrequent flushing, McGregor reports. Even when some of the presses are not running, oil recirculates back to the Pro Mix, reducing the likelihood of bacteria growth.

McGregor offers final thoughts:

“I fully expect a return-on-investment of 18 to 24 mo. on this system,” he says, “due to less spillage and eliminating other sources of waste. And, the operators, relieved of any responsibility to mix lube and deliver it to the presses, now spend more time at the presses, helping to increase overall equipment effectiveness.

“In the end,” he says, “operators readily accept change when it’s easy on them, and when it makes their jobs easier. That’s what we’re experiencing with our new focus on lubrication innovation.” MF

Industry-Related Terms: Blank, Blanking, Die, Draw, Drawing, Form, Hydraulic Press, Ram, Run, Transfer Die, Transfer, Ultrasonic
View Glossary of Metalforming Terms

 

See also: FUCHS Lubricants Co., Industrial Innovations, Inc.

Technologies: Lubrication

Comments

Must be logged in to post a comment.
There are no comments posted.

Subscribe to the Newsletter

Start receiving newsletters.