Aqueous Lubricant Composition for Cold Forming Metal Surfaces
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Solution Overview
Problem
Existing cold forming processes for metallic surfaces face challenges with high temperature viscosity issues, corrosion from sulfidic solid lubricants, and environmental concerns, requiring additional solid lubricants and complex coating sequences that increase costs and environmental impact.
Innovation Solution
Aqueous lubricant composition containing water-soluble oxides or silicates, ionomers, and non-ionomers, which forms a coating that reduces the need for additional solid lubricants, improves deformation capabilities, and enhances environmental compatibility by simplifying the coating process and facilitating the removal of residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sulfidic solid lubricants are used for cold forming, then lubrication performance is improved, but corrosion resistance deteriorates due to hydrolysis and sulfurous acid formation
Solution Approach 1:
The patent removes sulfidic solid lubricants from the lubricant composition entirely, replacing them with alternative lubricating agents that do not cause corrosion through hydrolysis and sulfurous acid formation
Solution Approach 2:
The patent introduces water-soluble oxides and silicates as intermediary substances that provide lubrication without the harmful corrosion effects of sulfidic compounds, acting as a mediator between the need for lubrication and the need to prevent corrosion
2Temperature
If additional solid lubricants are applied to handle high temperature viscosity issues, then lubrication at elevated temperatures is improved, but device complexity increases due to multiple coating steps
Solution Approach 1:
The patent combines multiple functional components (water-soluble oxides, silicates, ionomers, and non-ionomers) into a single lubricant composition that provides both low-temperature and high-temperature lubrication performance, eliminating the need for separate coating steps
Solution Approach 2:
The lubricant composition is designed to perform multiple functions across a wide temperature range, providing lubrication, viscosity control, and temperature resistance in a single formulation that works for both cold and hot forming operations
3Strength
If conventional lubricant compositions are used for severe cold forming, then deformation capability is limited, but tool wear increases
Solution Approach 1:
The patent creates a composite lubricant composition combining water-soluble oxides, silicates, ionomers, and non-ionomers that work synergistically to reduce friction and wear while enabling severe deformation operations without compromising tool life
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The lubricant composition allows for increased deformation and reduced tool wear, enabling more severe cold forming operations without additional solid lubricants, while being environmentally friendly and cost-effective, with improved corrosion resistance and easier residue removal.
Implementation Method 1
Aqueous lubricant composition containing water-soluble oxides or silicates, ionomers, and non-ionomers, which forms a coating that reduces the need for additional solid lubricants
Data Source
AI summary
The invention relates to a method for preparing metal workpieces for cold forming by applying a lubricant layer either to a metal surface or to a metal surface which has been pre-coated with e.g., a conversion coating. The lubricant layer is formed by contacting the surface with an aqueous lubricant composition which has a content in at least one water soluble, water-containing or water-binding oxide or silicate and a content in organic polymer material, the organic polymer material used predominantly being monomers, oligomers, co-oligomers, polymers and copolymers based on ionomer, acrylic acid/methacrylic acid, epoxide, ethylene, propylene, styrene, urethane, the ester or salt thereof. The invention to the corresponding lubricant composition, to the lubricant layer produced thereof and to its use.