Cooling and lubrication of automated forging processes with high-pressure systems

Abstract

During hot massive forming processes forge tools are exposed to high contact temperatures up to 1250°C. The cooling and the lubrication of forging dies of automated processes have to be effected in shorter cycle times within a small time frame at extremely high cooling rates. To reduce the thermal stress and to dissipate an increased heat quantity, a new concept for cooling a forging bolt has been developed. A high pressure system has been included additionally in an already existing low pressure spray system. The results of the conducted analysis verified a positive influence on the tool abrasion by using the high-pressure airless cooling in combination with common low-pressure cooling systems for local hard thermal stressed forging tools. The required quantity of cooling and lubrication solvent has been totally increased by additional admission of the high pressure spray head. To configure a high-pressure cooling lubrication of selected die areas it is necessary to expose the total surface of the forging tool via the presented geometry. Since the high-pressure technology does not provide for a nebulization of the cooling medium, the tool areas not directly exposed to the lubricant will not be coated. The application of the high pressure technology for additional cooling of highly stressed tool areas is especially relevant for circulation cooling lubrication systems. Due to the higher consumption of water and lubricant the application of the presented hybrid technology for systems with loss lubrication is neither ecologically nor economically suitable.