DEVELOPMENT OF CLEAN LUBRICATION SYSTEM WITH GOOD LUBRICITY IN MANUFACTURING PROCESSES

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The present developmental scientific research aimed to develope a clean lubrication system with good lubricity in manufacturing processes using ultrahigh molecular weight polyehylene based lubricant investigated by the head investigator et al.. The following conclusions were reached.1.It has been confirmed in forward extrusion type and ring compression type friction tests that a ultrahigh molecular weight polyethylene (UHMWPE) and a calcium stearate are superior in lubrictiy to other solid lubricants, and the water based UHMWPE lubricant has same lubricant has same lubricity as the water based graphite lubricant.2.A new friction testing method of forward-backward extrusion type was develped, enabling evaluation of lubricants for forging processes under more severe conditions than the upsetting such as ring compression test.The friction testing apparatus in which a high frequency induced heating system of workpiece, a spraying system of lubricants and an electric resistance heating system of die were installed into a mechanical press, was developed and manufactured.It has been confirmed by some friction tests that the values of friction coefficient or frction shear factor can be estimated reasonably with good reproducibility under the working conditions of 10ﾟ as the cone die half angle in forward extrusion and 25,50,70% as the reduction in area of backward extrusion.The UHMWPE lubricant and the graphite lubricant were tested in hot forgings of a stainless steel and aluminum alloys by the forward-backward extrusion type friction test, and those lubricants were evaluated in a workshop of hot forging of stainless steel. As a result, it has been confirmed that the clean lubrication system with good lubricity can be developed using the UHMWPE lubricant.