Evaluation of stamping lubricants at various temperature levels using the ironing test

Lubricants are employed in stamping operations in order to (a) improve the material flow into the die cavity, (b) reduce wear and galling in the die and (c) obtain good surface finish of the part. Process conditions such as high temperatures and pressures could cause the lubricant to fail, thus resulting in galling or tearing of the part, damage to the tooling, and lost production. Therefore, selection of an appropriate lubricant based on the process conditions is important in the stamping industry. Several benchmark tests emulating stamping operations have been developed and are used to evaluate the performance of candidate lubricants. The major drawback of most of these tests is their inability to emulate high contact pressures and sliding velocities, which are crucial parameters for lubricity, especially in the case of high-speed progressive or transfer die operations involving ironing. Moreover, most of these tests are conducted at room temperature, while in reality; the process temperature can reach as high as 200 °C. The ironing tribotest developed at the Engineering Research Center for Net Shape Manufacturing (ERC/NSM) induces high contact pressures and temperatures, thus emulating the conditions in a production environment. Application of the test to screen candidate lubricants for stamping operations involving the ironing process is discussed in this paper.