Wet blast/Water based lubricant application
WLS

WLS

What is WLS(Wetblast Lubricant System)?

WLS (wet blasting / water based lubricant application) is treatment equipment for the lubrication process of cold forging lines. By integrating the substrate treatment (oxidation scale removal, degreasing washing, fine irregularity formation) and lubricant application, the installation area is 1/10, the water consumption is 1/30, and the industrial waste is less than 1/20 compared to conventional lubricant system.

Features of WLS processing

  • Significantly shortens lead timesSupports up to 30 SPM while integrating scale removal and lubricant application
  • Rationalization / Cost reductionStreamlining through process shortening
  • High lubrication performanceMaximize the performance of the lubricant

Illustration of WLS treatment

WLS

Process

WLS

Comparison of process for WLS and zinc-phosphate + soap

WLS

Substrate treatment suitable for water based lubricant application "wet blast"

WLS

Wet blasting is a technique of spraying a mixture of water and abrasive at high speed with compressed air, then cleaning, processing and modifying the surface. Has the feature that fine abrasives can be used for wet treatment, and excels at forming fine irregularities while scraping off the workpiece surface together with dirt and foreign matter.

Surface after wet blast treatment

Surface after wet blast treatment

"Special stainless steel abrasive" for WLS

Special stainless steel abrasive for WLS

Performs oxidation scale removal / degreasing and fine irregularity formation using special sharp stainless steel abrasives. The highly tough abrasives contribute to reducing industrial waste.

Surface properties that improve trackability of the lubricant

The surface after wet blasting treatment has high wetness and can enhance the retention of the lubricant layer. As the lubricant tracks without layer breakage at the time of pressing, forging performance comparable to zinc-phosphate + soap can be obtained even with thin coatings.

Comparison of forging load for WLS and zinc-phosphate + soap

The basic surface of the workpiece is turned (Ra 0.8)

Setting area enlargement ratio
651%1004%1358%1712%2065%
WLSAdhesion amount: 5g/mLoad(KN)418420428433441
Seizure
Zinc-phosphate + SoapLoad(KN)422426431445Not-tested
Seizure

:No seizure, :Seizure occurs

Test conditions

  • Test method: Rear extrusion test
  • Test speed: 35 spm
  • Punch: HAP72
  • Workpiece: S10C spheroid annealed material
  • Workpiece temperature: room temperature

Illustration of test

Thin and uniform lubricant application

A "spray coating method," which is less prone to unevenness or lumps in water based lubricant application, is used to form a thin, uniform water based lubricating film. It is unnecessary to carry out a time-consuming initial make-up of electrolytic bath as the film is applied without elevating the liquid temperature or circulating it. Adjusting the injection volume gives the optimum adhesion weight for the workpiece and processing. Moreover, liquid exchange is simple, only requiring bottle replacement, eliminating the need for troublesome management unlike conventional chemical treatment.

Comparison of application methods

Dip method

Application unevenness occurs
-> Cause of scum clogging in the mold

Spray method

Thin and uniformly coated surface
-> Hard for lubricant scum to occur

Application example

Pin point
-> Reduce wasteful consumption of lubricant through accurate application

Coating system

Bottle supply
-> Easy initial make-up of electrolytic bath for single liquid and easy management of liquid

WLS device compatible with 30 SPM with no dents

wls equipment
  • Wet blasting substrate treatment and lubricant application in one unit
  • Scratch-free / dent-free treatment of workpiece
  • Thin and uniform water based lubricant film achieved by spray coating

Device treatment unit for billet

As the pawls move alternately, the workpiece is transported, and the roller rotates the workpiece.

Device treatment unit for billet

Device treatment unit for rings

The pawls lift the workpiece and carry it to the next roller. The roller rotates the workpiece.

Device treatment unit for rings