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This presentation gives successful industrial case studies of cost reduction in hot forging by the use of: 1. Anti-scale protective coatings to prevent rejections due to scaling, reduce or eliminate shot blasting, reduce decarburization in heat treatment, hot rolling and hot forging. 2. Environment friendly die lubricants that eliminate pollution and increase die life. 3. Zero maintenance die lubricant spraying systems that ensure maximum uptime and no unplanned downtime during hot forging.
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COST REDUCTION IN HOT FORGING BY
INNOVATIVE TECHNIQUES
byby SRIKAR SHENOYSRIKAR SHENOY
GENERAL MANAGER
211, RAIKAR CHAMBERS, GOVANDI EAST,
MUMBAI–400 088. INDIA.
Tel. : 91-22-6797 8060 Fax : 91-22-2555 2459
Mobile: 9820493373
Email : [email protected]
Website : www.steelplantspecialities.com
: SINCE 1985
Solving Problems Systematically
Through
• Innovative, customised products.
QUICK FACTS ABOUT SPS
Incorporated in 1985 by seasoned metallurgical engineers from Indian Institute of Technology, Mumbai.
Manufactures range of products for heat treatment, hot forging and hot rolling industries. ISO certified.
Sole supplier of specially developed niche products to industry leaders.
1. Cost Reduction through
Protective (anti-scale) coatings that prevent or minimize:
Oxidation (scaling) & decarburization during hardening, normalizing, hot rolling & hot forging.
Quench cracking. Shot blasting / pickling operations. Rejections during re-HT
HARMFUL EFFECTS OF OXIDATION AND HARMFUL EFFECTS OF OXIDATION AND DECARBURISATIONDECARBURISATION
1. Loss of dimension.2. Deterioration of surface quality, i.e., pitting.3. Non-uniform metallurgical transformation during hardening. 4. Lowered surface hardness and strength.5. Reduced fatigue life of heat treated product.
Concept: Protective Coatings to Concept: Protective Coatings to Prevent or Minimize OxidationPrevent or Minimize Oxidation
Oxidation & decarburization occur during heating in open air atmosphere due to surface reaction of metal and carbon with oxygen, and products of combustion.
STEELAIR
PREVENTING OXIDATIONPREVENTING OXIDATION
PROTECTIVE COATING
Protective anti-scale coatings form a barrier on metal that prevent reaction of metal with oxygen.
Hence, oxidation is either prevented or delayed.
Coated Billets before Hot Forging
Coated Components
before Heat Treatment
Characteristics of Characteristics of ESPON anti-scale coatingsESPON anti-scale coatings
Do not react with metal.
Do not emit toxic fumes during storage, use or during heating the coated job.
Non-hazardous.
Economical. Method of application: Brushing, Dipping or Spraying
Benefits of using protective coatings:Benefits of using protective coatings:
1. Preventing scaling and decarburization.
2. Preventing rejections due to quench cracking.
3. Elimination or minimization of post heat treatment operations like grinding, shot blasting or acid pickling.
4. Preventing rejections during re-heat treatment and re-re-working.
The next illustration shows material saving of more than 10% in an expensive metal alloy hot rolling operation.
Process improvement of 50% was noted due to reduction in grinding.
Huge savings were made possible by use of ESPON anti-scale coating.
CR Sheets
4300 mm X 1100 mm X 4.5 mm
ANNEALING
950ºC/30 mins./
air-cool to room temperature
HOT LEVELLING
820ºC/60 mins.
GRINDING
FINAL THICKNESS
3.7 mm
USE PROTECTIVE COATING
SCALE PREVENTION = MATERIAL SAVING + PRODUCTIVITY IMPROVEMENT
CR Sheets
4300 mm X 1100 mm X 4 mm
ANNEALING
950ºC/30 mins./
air-cool to room temperature
HOT LEVELLING
820ºC/60 mins.
GRINDING REDUCED BY 50%
FINAL THICKNESS
3.7 mm
Coated Split Rings before Heat Treatment.
After Heat Treatment & Shot Blasting
COATEDNOT COATED
Photo next to Customer’s Quality Department
Use of Protective Coating Use of Protective Coating
To To PreventPrevent Or Minimize
Rejections due to Quench Cracking
Product: Steering knuckle
Gear-end of crank shafts prone to quench cracks
Use of Protective Coating Use of Protective Coating
To To EEliminate Or Minimize
Operations Like
Shot Blasting, Grinding, Or Acid Pickling after Heat
Treatment.
Preventing scaling on the inner surface of Forged Spindles
STEEL PLATES
ANNEAL
SHOT BLAST
DESPATCH
SHOT BLAST
SHOT BLAST
ANNEAL AFTER ESPON COATING
SHOT BLAST
STEEL PLATES
DESPATCH
PRODUCTIVITY IMPROVEMENT DUE TO COATING
Above Details as confirmed by M/s. SAIL, Rourkela Steel Plant, Rourkela.
Use of Protective Coating Use of Protective Coating
To To
Salvage Rejected Components and to Prevent Salvage Rejected Components and to Prevent Rejections during Re-Heat TreatmentRejections during Re-Heat Treatment.
REJECTED COMPONENTS(HEAT TREATED)
(METALLURGICAL REASONS)
SCRAPSALVAGE BY
RE-HEAT TREATMENT USING
PROTECTIVE COATING
Re-Heat Treatment of Finish Machined Forged Spindles
Image on left shows heat treated spindles. Image on Right shows a re-heat
treated spindle. Zero Scaling + Aesthetic appeal
Heavy scaling leads to pit-marks on forgings during re-working.
Scale-pits are prevented by use of anti-scale coating during re-work. Identification numbers are intact.
2. Cost Reduction through
Hot Forging Die Lubricants that:
Eliminate pollution
Are environment friendly
Ensure optimum die life
Enable smooth production in a number of hot forging operations
Are economical
Types of Hot Forging Lubricants Manufactured by SPS:
• Graphiteless, water soluble
• Graphite based, water miscible
• Special oil with graphite
• Special oil without graphite
• Uniformity in metal flow.
• Parting compound.
• Barrier to heat transfer.
• Prevent build up in die cavity.
• Be easily removable.
• Avoid explosion due to rapid phase change.
• Environment friendly.
• Economical.
CHARACTERISTICS OF ESPON DIE LUBRICANTS
METHODS OF APPLICATION
• Manual swabbing
• Dipping (extrusion punches)
• Manual Spraying
• Automatic Spraying
Coming up:
Case Studies of ESPON hot forging die lubricants as confirmed by customers in India and some testimonials.
Productivity Improvement
Sr.No
Particulars Graphite Based Lubricant
Graphiteless Lubricant ESPON-
GLF3
1. Forging equipment 1000 Ton Press
2. Product Sleeves
3. Dilution ratio 1:10 1:10
4. Time loss due to die grinding at each shift
1.5 hrs NIL
5. Production per day 7000 9000
6. Productivity improvement -- 22%
Cost Benefit Analyses 1
Sr.No
Particulars Lubricating Oil Graphiteless Lubricant ESPON-GLF3
1. Forging Equipment 1000 Ton Press
2. Product Companion Flange
3. Die Life 4500 6000
(33% Improvement)
4. Price Rs. 24/- per ltr. Rs. 17/- per ltr.
(1:7 dilution)
5. Application Swabbing Spraying
6. Pollution Heavy smoke Clean environment
Cost Benefit Analyses 2
Sr.No
Particulars Lubricating Oil Graphiteless Lubricant ESPON-GLF3
1. Forging Equipment 1600 Ton Press
2. Product Input Shaft (Indica car)
3. Die Life 5000 7000
(40% Improvement)
4. Price Rs. 24/- per ltr. Rs. 12/- per ltr.
(1:10 dilution)
5. Application Swabbing Spraying
6. Pollution Heavy smoke Clean environment
Seeing is Believing!
• Application Videos.
Videos of ESPON hot forging lubricants and Spraying Equipments in action available on given links:
Oil lubricant on 1000 ton press: http://bit.ly/dielubeOil
ESPON Environment friendly lubricant on 1000 ton press: http://bit.ly/ESPON-DEL3
Environment Friendly Indeed!
• MITCON Tests.
Workzone Air Quality Comparison Summary.
Parameters Units Imported Graphite Based Lubricant
ESPON
Graphiteless Lubricant
Suspended Particulate Matter
µ g/m3 509 362
(29% Less)
Sulphur Dioxide µ g/m3 33.60 32
Oxides of Nitrogen µ g/m3 42.50 41
Carbon Monoxide µ g/m3 8 3
(63% Less)
3. Cost Reduction through
Zero Maintenance Die Lubricant Spraying Systems
Ideal Features of Die Lubricant Spraying System:
Ability to deliver all types of die lubricants.
Continuous automatic stirring / agitation.
Quick re-filling.
Economical.
Long life and low running costs.
Zero unplanned downtime.
Low maintenance.
Low inventory costs.
Diaphragm Pump Spraying Equipment
Diaphragm Pump Spraying Equipment
Ability to deliver all types of die lubricants. Continuous automatic stirring / agitation. Quick re-filling. Economical. Long life and low running costs. Zero unplanned downtime. Low maintenance. Low inventory costs.
Conventional Pressure Feed Tank
Ability to deliver all types of die lubricants. Continuous automatic stirring / agitation. Quick re-filling. Economical. Long life and low running costs. Zero unplanned downtime. Low maintenance. Low inventory costs.
Pressure Feed Tank with Motor
Ability to deliver all types of die lubricants. Continuous automatic stirring / agitation. Quick re-filling. Economical.Long life and low running costs. Zero unplanned downtime. Low maintenance. Low inventory costs.
Zero Maintenance Pressure Feed Tank
Ability to deliver all types of die lubricants. Continuous automatic stirring / agitation. Quick re-filling. Economical. Long life and low running costs. Zero unplanned downtime. Low maintenance. Low inventory costs.
Zero Maintenance Pressure Feed Tank
Videos
Accessories - Sprayguns
Accessories – Foot Operated Spray + Nozzles
Accessories – Spray Nozzles
SUMMARY
Substantial cost reduction in hot forging is possible by the use of:
1.Protective anti-scale coatings
2. Environment friendly forging die lubricants
3. Zero Maintenance Spraying Systems
Manufactured by SPS.
TESTIMONIALS
Testimonials from industry leaders who are regular satisfied users of ESPON products mentioned in this presentation are available on request.
We put new LIFE into your die and forging process!
www.steelplantspecialities.com
