Lubrication is a common practice in sheet metal processing and is routinely used in many industrial applications. It is crucial for manufacturing processes such as punching, bending, cutting and forming, as it reduces friction and extends tool life. The type of lubrication used affects both the quality of the parts and the efficiency of the process.
Optimal lubrication not only extends the service life of tools and machines but also improves surface quality by minimising scratches and damage. In today’s industry, the correct lubrication is therefore not only a technical necessity, but also an important aspect of responsible management.
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Conveyor belt and tool lubrication processes
There are several systems for belt and tool lubrication, each with its own advantages and areas of application. The most common lubrication systems can be divided into two main categories: roller lubrication and non-contact methods.
Roller lubrication
In this process, the lubricant is applied to the surface of the workpiece or tool by special rollers. This method allows the lubricant to be distributed evenly.
Contactless methods
These systems, on the other hand, work without direct contact between the lubrication system and the workpiece. They use technologies such as spray and application valves to apply the lubricant selectively and precisely. Contactless lubrication systems offer decisive advantages in applications where contact during transfer must be avoided to prevent contamination.
However, there are various possibilities and scopes for non-contact lubrication processes. For example, WERUCON® offers interesting new ways to optimise and individualise processes for smaller high-speed machines.
Innovative solutions for high-speed machines
WERUCON® specialises in developing process-oriented approaches for conveyor belt and tool lubrication that both optimise machine performance and significantly reduce operating costs.
WERUCON®’s process-oriented solutions focus on the specific needs of high-speed machines. These machines are designed to produce high volumes in the shortest possible time, which requires consistent and reliable lubrication. The implementation of modern lubrication technologies ensures that the tools and machines operate under optimal conditions.
- Adaptive lubrication systems enable real-time lubricant delivery.
- Lubrication systems can be seamlessly integrated into existing machine controls.
Another key aspect of the WERUCON® solutions is that they consider economic and environmental factors. The optimised lubrication systems not only help to reduce costs but also support sustainable manufacturing practices.
- Reduction of lubricant consumption is achieved thanks to precise dosing and adaptive control of the lubrication systems.
- Longer tool life is achieved through effective lubrication that reduces wear on tools and machines.
Requirements for modern lubrication systems
Modern lubrication systems must meet key requirements. In addition to efficiency and speed in terms of optimal lubrication, the economic aspect is also particularly important. Cost reduction can be achieved through technologies such as minimal quantity lubrication (MQL) and maintenance-friendly designs without long downtimes.
Lubrication systems should be modular and versatile so that they can be easily adapted to different products and processes. This increases flexibility and reduces investment costs.
Minimum Quantity Lubrication (MQL)
What is Minimum Quantity Lubrication (MQL)? Minimum Quantity Lubrication uses only very small amounts of lubricant, usually applied in the form of a fine film. This enables precise dosing and reduces lubricant consumption in strip and tool lubrication.
Minimum quantity lubrication is used in a variety of applications. It is particularly effective in metal cutting, sheet metal processing and assembly processes. MQL increases efficiency and competitiveness in manufacturing. Other important factors include lubrication frequency, dosing and possible re-lubrication.
The advantages are clear:
- lower lubricant consumption reduces operating costs
- environmentally friendly, less waste and lower environmental impact
- improved product quality minimises residues and optimises surface quality
- longer tool life thanks to reduced wear and frequent tool changes
Lubrication frequency and dosing
The lubrication frequency and dosage are crucial for the effectiveness of lubrication systems. Precise adaptation of the lubricant quantity to the operating speed and the specific machining conditions ensures that both precise lubrication and minimisation of lubricant consumption are achieved.
WERUCON® provides highly efficient volumetric dosing pumps for this purpose. These pumps enable precise dosing of the lubricant, regardless of the production conditions.
Punctual re-lubrication in the tool
Punctual re-lubrication is a targeted lubrication technique that is designed to apply lubrication directly to the relevant contact points in the tool. Thanks to innovative engineering service providers such as WERUCON®, numerous products have been developed for these processes.
- special nozzles: These are designed to apply lubricant precisely where it is needed, ensuring effective lubrication without overdosing.
- coaxial quick couplings: These enable quick and easy replacement of metering nozzles and contribute to the efficiency of the lubrication process by facilitating maintenance and adjustment of the lubrication systems.
Reducing lubricant consumption
Reducing lubricant consumption is crucial to the efficiency of lubrication systems. Precise metering and adaptive lubrication techniques minimise consumption, resulting in cost savings and a lower environmental impact. In addition, efficient lubrication improves process reliability and extends the service life of tools and machines.
Containment and space requirements
Many lubrication systems require a housing to protect the lubricants from contamination and to increase safety. With WERUCON® technology, low-mist, precise application is possible for strip and tool lubrication. This increases the safety of the entire work area (workpiece, tools, machine). This is because the risk of unwanted oil carryover is greatly reduced and a housing for the lubrication process is no longer necessary.
Prospects for lubrication technology
The future of lubrication technology will be characterised by advanced developments in dosing technology and the use of intelligent automation solutions. WERUCON® has developed innovative solutions for high-speed machines up to 100 tons and their special requirements:
- space-saving
- expandable
- easy to retrofit
Furthermore, the focus on sustainable and environmentally friendly concepts will increase. New materials and bio-based lubricants will come to the fore in order to reduce the ecological footprint of manufacturing. At the same time, effective lubrication processes are essential in modern sheet metal processing to increase productivity. Continuous research and development in this area will help to make lubrication systems even more effective, safer and more environmentally friendly, which will ultimately strengthen the industry’s competitiveness.
Insights from developments
Conveyor belt and tool lubrication plays a crucial role in sheet metal processing, particularly in increasing efficiency and reducing costs in modern manufacturing processes. Innovative solutions such as minimum quantity lubrication and selective re-lubrication enable low-residue oiling and significantly reduce grease consumption.
Future developments in dosing technology and compact housing systems, or the elimination of the need for such systems, promise further optimisation and improved process reliability. Lubrication technology will continue to play a central role in the competitiveness of industry.