ENGINEERED Fluid Dispensing has written about the challenges of applying lubrication to metal stamping processes.
Metal stamping processes require lubrication to minimize friction, dissipate heat, reduce tool wear and maintenance, and prevent galling.
Unfortunately, standard lubrication systems like pads, rollers and airless sprays do not usually apply a consistent coating of oil to the stock.
To compensate, many stampers end up applying at least 50% more lubricant than what is actually needed.
While overlubrication does prevent dry spots, in most instances it also increases pressroom safety problems like airborne mist, dermatitis, and slippery pressroom floors. Environmental issues like volatile organic compound (VOC) emissions, along with increased hazardous waste storage and disposal, also arise when too much oil is applied.
Repeated contact with metalworking fluids, either from spreading lubricant on, wiping it off, or handling absorbents and other hazardous waste, can cause skin irritation and dermatitis.
When oil is vaporized by the force of the stamping press, it forms a mist that can irritate the eyes, nose and throat, cause breathing difficulties, and collect on equipment and floors. With water-soluble lubricants, the lubricant is carried with the steam produced when water hits the hot tooling surfaces.
Most occupational health and safety processionals recommend an exposure limit of 0.4mg per cubed meter for up to 8 hours per day during a 40-hour work week.
When too much oil is applied, or when lubrication systems drip and won't shut off, equipment and floors can become slick with oil. The excess oil must be collected with mops or absorbent materials, further increasing the risk of skin problems from handling hazardous waste.
Overlubrication can also damage the environment, with hazardous emissions of Volatile Organic Compounds, toxic waste, and excessive consumption of resources.
According to the company, low volume low pressure (LVLP) Technology can resolve lubrication-related problems. It is said to integrate precision flow controls for instant response to coverage adjustment, depending on the stock and lubricant viscosities.
The new technology applies oil at two to three psi, compared to traditional airless sprays which use up to 1000 psi, causing oil to bounce off the stock into the air and onto the floor.
A typical LVLP lubrication system consists of precision LVLP valves; a lubricant reservoir; and a valve controller that regulates air pressure, meters lubricant flow, and controls valve operation.
When the system is activated, air pressure is applied to the lubricant reservoir, which pushes lubricant through the flow controls inside the valve controller and out to the valves.
As soon as the press begins stamping, the system is activated by a solenoid wired into the press controls. As the valves open, LVLP air at 2-3 psi creates a pressure drop at the nozzle, causing a fine, even film of lubricant to be applied to the stock surface.
LVLP lubrication is said to eliminate mist and the need to wipe oil on or off stock. By reducing contact with the lubricant, the potential for dermatitis is reduced.
The consistent and fine application of oil reduces dripping and puddles, cutting cleanup times and hazard. It also reduces oil use between 50 to 90%.

Key contact:
EFD
info@efd-inc.com

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