Planned lubrication

What is planned lubrication?

Planned lubrication refers to the targeted, process-safe application of lubricants to sheet, tools or components based on clearly defined parameters. Unlike conventional methods such as continuous lubrication (also called non-stop lubrication), metering without sensors, or manual application, planned lubrication is built on the systematic integration of lubrication strategies into the production process.

This includes factoring lubrication into tool design from the outset, as well as control via digital components such as sensors and valve technology. The goal is a reproducible, pinpoint, clean and economical lubricant application tailored to the workpiece, tool and process speed.

Practical problems and risks of unplanned lubrication

Many manufacturing plants still rely on drip methods, manual dispensers or systems without feedback. These techniques carry significant risks: uncontrolled oil application leads to overdosing – particularly when the machine is stopped – which increases consumption as well as cleaning and disposal costs.

Inadequately lubricated parts also lead to scrap, tool wear and production stoppages. Follow-on costs range from increased maintenance to unplanned downtime.

Why targeted lubrication is indispensable in the stamping process

In stamping, the lubricant performs several essential tasks: it reduces friction, controls temperature, prevents material build-up and ensures consistently high workpiece quality. Without sufficient or uniform lubrication, the risk of tool wear, scrap or even machine damage increases.

Environmental aspects such as oil mist or droplets can also create workplace issues and extra cleaning effort. Controlled, plan-based lubrication remedies this, ensuring each application precisely matches the tool and material requirements.

Transferability: sectors and processes with similar requirements

While planned lubrication has proven particularly effective in stamping, the principle extends to many other manufacturing processes. In assembly – such as pressing in O-rings or seals – precise spot lubrication is just as critical as in thread forming or metal forming.

Get advice on systematic lubrication now

Exact lubricant application is increasingly required in sawing processes as well. The technology therefore offers immediate potential in related sectors, helping to improve quality, economics and sustainability.

Technical approaches to planned lubrication

The market today offers numerous systems for targeted lubricant applications, including the Electronic Dosing Centre (EDC). It features digital controllability, modular design and real-time regulation.

Werucon’s system supports up to eight dosing pumps with servo-driven control and eight dosing-nozzle connections, allowing flexible adaptation to different production scenarios. All parameters can be set and monitored intuitively via the touch display. Integrated monitoring ensures a constant lubricant supply, minimises downtime and prevents over- or under-dosing.

Economic and environmental benefits

Planned lubrication can drastically reduce lubricant costs – by up to 70 % in some cases. At the same time, tool life increases as friction and heat are minimised.

Further benefits include fewer cleaning cycles, elimination of oil-mist hazards and lower environmental impact. Modern systems such as Werucon’s combine these effects into a clear sustainability advantage – without compromising production speed.

Lubrication technologies in planned lubrication

Ease of operation, serviceability and integration into existing control systems also matter. Environmental criteria such as avoiding oil mist, recirculating excess oil and energy consumption are further evaluation points.

Spray lubrication – flexible, precise, digitally controllable

• Oil is sprayed onto the surface via fine nozzles, e.g. using an in-line spray system (DSS).
• It can be divided into zones (e.g. edges, centre, localised points).
• It is digitally controllable via machine-cycle signals or sensor feedback.
• Advantages:
  • individual lubrication by workpiece zone
  • very suitable for changing part geometries or production lines
  • reduced consumption through demand-driven dosing

Internal lubrication – directly in the tool

• Lubricant is supplied through integrated channels in the tool or via defined points.
• Particularly suitable for punching and punch-tip lubrication, or for internal tube wetting.
• Advantages:
  • no excess, as application is limited to where it is needed
  • tight coupling to the tool process – ideal for tight tolerance requirements
  • enables directed material flow in the die (e.g. during deep drawing)

Planned lubrication with Werucon

Werucon makes planned lubrication measurable and reliably implementable in industrial environments. Combining modern technology with practical consulting, Werucon ensures that planned lubrication not only extends tool life, reduces scrap and increases process reliability, but also enables a sustainable approach to lubricants. The system is therefore a central building block for integrating planned lubrication effectively into production.

Read a further in-depth article on the subject here (only available in German) – it was published by the trade press BLECH Stanztec Spezial.