In the production of iron stamping slide rails, the wear rate of the die directly affects product quality, production efficiency, and die life. Lubrication technology, as a core means of reducing friction and wear, directly determines the stability and economy of the production process. In the complex forming process of iron stamping slide rails, the high-pressure, high-speed relative motion between the die and the material generates a large amount of heat. If lubrication is insufficient, frictional heat will accelerate the peeling of the hardened layer on the die surface, leading to wear problems such as edge dulling, groove formation, and rounding of corners, which in turn causes defects such as dimensional deviations and decreased surface quality. Therefore, a systematic solution needs to be constructed from three aspects: lubricant selection, lubrication method optimization, and process synergistic control.
Matching the performance of the lubricant is fundamental to reducing die wear. In the production of iron stamping slide rails, the die must withstand high-pressure stamping and complex bending deformation of high-strength steel plates, requiring the lubricant to simultaneously possess extreme pressure anti-wear properties, cooling properties, and adhesion properties. Traditional oil-based lubricants, while forming a lubricating film, are prone to oxidation and decomposition at high temperatures, producing sludge that accumulates in the mold cavity and exacerbates wear. Water-based lubricants, with the addition of extreme pressure additives, can form a chemically adsorbed film on the mold surface, transforming the friction type from dry friction to boundary lubrication and significantly reducing wear. For example, water-based lubricants containing sulfur and phosphorus extreme pressure additives can undergo a chemical reaction upon contact between the mold and the material, generating a low-shear-strength iron sulfide or iron phosphate film, effectively isolating direct metal-to-metal contact and thus extending mold life several times over.
Optimization of lubrication methods requires targeted design based on the structural characteristics of slide rails. Iron stamping slide rails typically contain precision components such as linear guides and ball screws, and their mold cavities are complex and often deep. Traditional manual application of lubricant can easily lead to uneven coverage and insufficient lubrication in certain areas. An automated spraying system is employed, using high-pressure nozzles to atomize the lubricant and evenly spray it onto the mold surface, ensuring lubricant penetration into deep cavities and corners. For continuous stamping production lines, a circulating lubrication system is installed, filtering used lubricant and re-injecting it into the mold, maintaining lubrication effectiveness while reducing lubricant consumption. Furthermore, for the slide rails bending process, a roller coating process can be used, using rotating rollers to evenly coat the lubricant onto the sheet metal surface, avoiding forming defects caused by lubricant accumulation.
Synchronous control of lubrication and cooling is crucial for suppressing thermal wear in molds. During iron stamping, the heat generated by material deformation can raise the mold temperature to several hundred degrees Celsius. High temperatures reduce the surface hardness of the mold, accelerating wear. At this time, the lubricant must also perform a cooling function, quickly removing heat to maintain a stable mold temperature. Water-based lubricants, due to their high specific heat capacity and high latent heat of vaporization, have a superior cooling effect compared to oil-based products, making them particularly suitable for high-speed stamping scenarios. For example, in the slide rails punching process, using a water-based lubricant can lower the mold temperature, effectively delaying the initiation of thermal fatigue cracks. Simultaneously, by adjusting the lubricant spray volume and frequency, a dynamic balance between lubrication and cooling can be achieved, preventing insufficient cooling due to excessive lubricant or lubrication failure caused by insufficient spraying.
The combination of mold surface treatment and lubrication technology can further enhance wear resistance. Surface coating treatments for molds, such as hard chrome plating or coating with a titanium nitride (TiN) film using physical vapor deposition (PVD) technology, can significantly improve the surface hardness and wear resistance of the mold. In this case, the role of the lubricant changes from simply reducing friction to assisting in protecting the coating, preventing it from peeling off due to localized overheating or mechanical impact. For example, in slide rails bending dies, using hard chrome plating followed by a water-based lubricant can significantly extend the mold's lifespan.
The establishment of lubrication management standards is fundamental to ensuring long-term stable lubrication performance. A system for regular lubricant testing and replacement should be established. By monitoring the lubricant's viscosity, acid value, and impurity content, deteriorated lubricants should be replaced promptly to prevent abnormal mold wear caused by lubricant performance degradation. At the same time, lubrication technology training is provided to operators to ensure that they master the correct amount of lubricant to add and the spray parameter settings, so as to avoid lubrication problems caused by improper operation.
