Modern Lubricants for Tube Bending. Christopher Fletcher, ChE Tower Oil & Technology Co.

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1 Modern Lubricants for Tube Bending Christopher Fletcher, ChE Tower Oil & Technology Co.

2 Outline Selecting Lubricants Why? Tools Chemistry Steps Today s Choices Lubricants Substrates & Sizes Wear Tooling Application

3 Do I Have To? Not Always. However

4 Why Lubrication? Photos courtesy of thefabricator.com

5 Why Lubrication? F f = μ N where F f = frictional force μ = coefficient of friction N = normal force Lower μ is desirable

6 Tools Twist Compression Test (TCT) Scientific Bench Test Very High Interface Pressures Variable Test Materials Lubricant Starvation Low Speed

7 TCT

8 TCT

9 TCT Coefficient of Friction ,000 psi 1650 W Time (s) Interface Stress (MPa)

10 TCT Comparing Two Gel Products

11 Chemistry Viscosity or Thick Film

12 Chemistry Boundary Create space to keep asperites from touching

13 Chemistry Extreme Pressure (EP) Use iron in metal to form chemical reaction Cl = Iron Chloride S = Iron Sulfide P = Iron Phosphate

14 Key Steps Health & Safety Considerations Chemical Content or Restrictions Waste Disposal Application

15 Key Steps Desired Residue Secondary Operation Compatibility No Adverse Effects on Material, Tooling, or Equipment Quality Parts & Acceptable Tool Life

16 Today s choices

17 Preferred Lubricants Synthetic Chemical Solutions Seed Oil Compounds Renewal Resource Soluble Oils Gels Pastes Compounded Oils

18 Synthetic Chemical Solutions Varying viscosities Dilutable Easy to wash Weld over lube residue True solutions or dispersions Lube does not drip out in paint oven Use when welding and/or painting are required Can be viscosity, boundary, and EP

19 Seed Oil Compounds Vegetable and/or renewable Minimal lubricant required (MQL) Lost lubricant theory No oily mess at machines No parts washing Weld over lube residue No waste disposal Usually viscosity and boundary

20 Soluble Oil Very Versatile Lube All Metal Safe Use neat or diluted Mix with water Easy to clean Can be viscosity, boundary, and EP

21 Emulsions Oil In Water Water in Oil

22 Gels Contain no mineral oil Very clean High water content Good weld through Mostly viscosity and barrier Not all work on aluminum Need controlled application

23 Necessary Gel Features Does not harden in drum or mandrel No slumping on mandrel under heat Does not drip out of tubes in-process Pump-able from drums/pails Come with drums liners

24 Paste Contain mineral oil and water Form an invert emulsion to thicken Typically blended with lubricity and/or EP or solid film lubricants for tougher applications Modern high quality pastes do not harden like a rock Can be cleaned and conducive to secondary processing

25 Compounded Oils Wide range of viscosities Typically used for extreme pressure lubrication Easy to pump or apply Additives to improve cleaning

26 So much to choose from There are many products within each family of lubricants. The individual products range from Light Duty to Medium Duty to Heavy Duty and in some cases Extreme Duty.

27 Order Light Duty Diluted Synthetics & Soluble Oils Seed Oil and Renewable Resource Gels Medium Duty Synthetics Seed Oil & Renewable Resource Soluble Oils Gels & Pastes

28 Order Heavy Duty Synthetics & Soluble Oils with EP Seed Oil and Renewable Resource with Boundary and/or EP Thicker Gels and Pastes with Boundary or EP Compounded Oils Extreme Duty High viscosity Soluble Oils with EP High viscosity Gels & Pastes with EP High viscosity Compounded Oils with EP

29 Lubricant Performance Variables Degree of Bending Diameter of Tube Substrate Material Thickness Tooling

30 D of Bend Use the degree of bend (D) to help determine how heavy duty the lubricant needs to be Photo courtesy of Tools for Bending D of Bend = CLR OD Example: 4 CLR 2 OD = 2 D

31 Rule of Thumb To help select bending lubricants, use the following rules of thumb 3 OD and < 2 D Bend: Use Heavy Duty Lube 3 OD and 2 D Bend: Use Light or Medium Duty Lube

32 Rule of Thumb > 3 OD and < 2 D Bend: Use Heavy or Extreme Duty Lube > 3 OD and 2 D Bend: Use Medium or Heavy Duty Lube Use heavier duty lubricant as: OD increases Thickness increases

33 Substrates Steel Seed Oils & Renewable Resource Gels Pastes Compounded Oils Aluminum Gels Pastes Renewable Resources

34 Substrates Stainless 4xx Series Seed Oils & Renewable Resource Gels 3xx Series Seed Oils & Renewable Resource Pastes Compounded Oils Aluminized Stainless Same as above only more paste

35 Substrates Copper/Brass/Softer Metals Seed Oils & Renewable Resource Synthetic (compatible) Soluble Oils Inconel/Titanium Pastes Compounded Oil

36 Tooling Mandrel AMPCO Bronze 18, 21, M4 are most common Soft = wears quickly Used on steel, stainless New coatings extending life Photo courtesy of Omni-X All lubricants

37 Tooling Mandrel Steel Harder Chromed; Other coatings Longer life but more wear on tube Photo courtesy of Omni-X Use on steel, stainless, aluminum, aluminized, and softer metals Higher end lubricants

38 Tooling Mandrel Plastic Becoming more useful Soft = wears quickly Used on helix, continuous, short run large Light lubricant

39 Tooling Mandrel New Material Longer life Acts like coating Light lubricant Photo courtesy of Tools for Bending

40 Tooling Wiper AMPCO Bronze Flexible Steel D2, S7, H13 Photo courtesy of Omni-X Some coatings on both, but cannot be brittle

41 Tooling Cutoff Knives High Speed Steel TiN Coating

42 Application Synthetic Chemical Solutions, Soluble Oils & Compounded Oils Basic fluid pump Bender turns on and off Air/electrical operated 1:1-5:1 ratio

43 Application Synthetic Chemical Solutions, Soluble Oils & Compounded Oils Air over lube tank with solenoid Electrical operated Bender sends signal but PLC can manipulate Photo courtesy of Industrial Innovations All can be sprayed or injected into locations depending on viscosity

44 Application Seed Oil Compounds & Renewable Resource Micro-mist Air or electrically operated Bender controls frequency

45 Application Gels & Pastes Air operated drum/pail pump Depends on viscosity Light = 5:1 ratio fluid pump Heavy = 15:1-50:1 grease pump; follower plate Metering system For < 4 OD Valves or metering pumps Bender controlled for each lube point

46 Matrix Substrate Thickness OD Typical Mandrel Material Bronze Mandrel Lube Synthetic Seed Oil Soluble Oil Gel Application Micro Mister Drum pump Drum pump/metering system Can be very large Generalities Rules of thumb Locked variables Narrows down quickly Multiple parts per bender Carbon Steel Thin Heavy < 3" > 3" < 3" Steel Chromed Bronze Steel Chromed Bronze Steel Chromed Bronze Paste Compounded Oil Synthetic Seed Oil Soluble Oil Gel Paste Compounded Oil Synthetic Seed Oil Soluble Oil Gel Paste Compounded Oil Synthetic Seed Oil Soluble Oil Gel Paste Compounded Oil Synthetic Seed Oil Soluble Oil Gel Paste Compounded Oil Synthetic Seed Oil Soluble Oil Gel Paste Compounded Oil Synthetic Seed Oil Soluble Oil Gel Drum pump Drum pump/metering system Micro Mister Drum pump Drum pump/metering system Drum pump Drum pump/metering system Micro Mister Drum pump Drum pump/metering system Drum pump Drum pump/metering system Micro Mister Drum pump Drum pump/metering system Drum pump Drum pump/metering system Micro Mister Drum pump Drum pump/metering system Drum pump Drum pump/metering system Micro Mister Drum pump Drum pump/metering system Drum pump Drum pump/metering system Micro Mister Drum pump Drum pump/metering system > 3" Steel Chromed Paste Compounded Oil Synthetic Seed Oil Soluble Oil Gel Paste Compounded Oil Drum pump Drum pump/metering system Micro Mister Drum pump Drum pump/metering system Drum pump Drum pump/metering system

47 Conclusion Method to the madness Run through selection steps Gather data Key in on performance, then optimize Consider application methods Consult lube and tooling suppliers

48 Sources Grinelli, Tony. "When a Good Tube Bends Bad - Part II." TheFabricator.com. N.p., 11 Apr Web. 28 Sept Tools for Bending Bend Tooling OMNI-X

49 Thank You Christopher Fletcher, ChE Tower Oil & Technology

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