A Tailored Forging Lubricant for Quality, Competitiveness, and Cost Savings
Aalberts Integrated Piping Systems Ltd is a global leader in the manufacture of advanced plumbing, heating and engineering products. With a history dating back to the 1890’s, the company’s commitment to quality, innovation and customer service has earned it an excellent reputation. The company boasts an unrivalled list of market leading product brands including the British made Yorkshire integral solder ring fittings, Pegler Terrier radiator valves, VSH Tectite push fit fittings, VSH PowerPress products, VSH Shurjoint solutions, the VSH XPress press fit system, Pegler valves, Prestex general brassware, Endex solder ring and Kuterlite compression fittings.
Lubricant Requirements
Aalberts Integrated Piping Systems Ltd’s Yorkshire site operates hydraulic and Hydromec presses, running a hot forging process that produces a variety of brass components, in a range of sizes. A forging lubricant is required to ensure a good release from the die, good material flow, and consistent surface quality of the components. While setup is carried out manually, the process is automated thereafter, making reliability a key requirement for the lubricant used, as is process efficiency.
In 2019, oelheld UK was consulted as part of a review of the lubricants currently in use. oelheld UK MD Pete Mangan and oelheld GmbH forging specialist Marius Schmid attended site to conduct an initial process analysis which identified that changes in viscosity and lubricant quality could improve process performance, prevent excessive build up within the dies, and offer the potential for a single product to be used on both presses.
AirForge Solution
oelheld’s AirForge product offering for forgers initially started out as a range of glass coating lubricants, specifically designed for the aerospace industry. The range has since grown to incorporate water-miscible and oil-based coatings, synthetic and hybrid options, with or without graphite (i.e. black or white), for both hot and warm forging industries.
“Our work in the field of forging lubricants has largely been driven by existing customer requirements. The AirForge range has a variety of off-the-shelf products but our extensive experience in the manufacture of oil-based products and dedicated forging specialists means we are able to develop new products tailored to a customer’s specific requirements. This was the case with the product we created for Aalberts Integrated Piping Systems Ltd which was custom made by our laboratory team in Germany.” - Marius Schmid (Forging Specialist, oelheld GmbH)
Following some initial testing, a low viscosity oil-based graphite product was put forward as a single solution for Aalberts Integrated Piping Systems Ltd’s multiple forging presses which were in fact designed to work with an oil based lubricant. Oil offers slightly better lubrication than water-based products and protects the machine better from corrosion. An oil base also allowed the viscosity to be tailored in such a way that the lubricant could be used on both machines, simplifying the processes and streamlining future consumable spend. The graphite content was measured to provide the exact amount of lubrication, flow and separation properties to offer consistency in quality and protect the dies.
The Results
We are pleased to say that following a successful trial period, Aalberts Integrated Piping Systems Ltd has made the switch to the custom AirForge product, having seen significant benefits with the new lubricant. Overall, improvements have been seen in component quality, the life of their hydraulic dies extended, reduced maintenance requirements of the Hydromec dies, reduced risk of combustion within hydraulic processes, and an increase in press speeds has been possible, especially for higher complexity components. What’s more, although the new lubricant represents a step up in quality (thanks to the higher graphite content, higher flashpoint and newer fluid technology), and one which has been specifically tailored to their requirements, the tailored lubricant also offers a significant annual saving, both in terms of product cost, and consumption - a much smaller quantity is required for effective lubrication.
By taking advantage of the latest advances in forging fluid technology and investing time in the development of a solution tailored to their requirements, Aalberts Integrated Piping Systems Ltd has shown that its ongoing commitment to a philosophy of quality, service, investment, competitiveness, and innovation provides a successful recipe for continuous performance and efficiency improvements. This type of proactive approach, even when applied to individual elements of the manufacturing process, can highlight opportunities for enhanced performance, reduced costs and ultimately add contribute to the adding value across a product range. If you have any IPS piping system or individual valve, fittings or piping component requirements please contact Aalberts Integrated Piping Systems Ltd’s UK sales team on freephone 0800 156 0010.
To discuss your forging lubricant requirements please feel free to get in touch with our technical team on 01745 814 77
It is always worth conducting regular reviews of the fluids you’re using as oftentimes innovations in fluid technology mean you can enhance performance without having to increase costs. Being oelSmart isn’t always about going for the most expensive option but about taking the time to find the right fluid for your processes to give you optimum performance, productivity, and worker protection.