Few things are more important in the metal stamping industry than adequate in-die lubrication and coil stock lubrication systems. But what are they exactly?  What are your options and how do you decide what's best for your needs?  Let's dive in!
 

What Are In-Die Automatic Lubrication Systems?

In-die automatic lubrication systems are specialized mechanisms designed to apply lubricant precisely within a stamping die during metal forming processes. These systems ensure that moving parts, such as punches, dies, and slides, receive the right amount of lubrication at the right time. Below we look at why they matter.
 

Importance of In-Die Lubrication Systems

1. Reduced Wear and Friction:

   • Proper lubrication minimizes wear and friction between metal surfaces, extending tool life and reducing maintenance costs.

2. Enhanced Part Quality:

   • Consistent lubrication prevents galling, scoring, and surface defects on stamped parts.

3. Increased Productivity:

   • Automated lubrication eliminates manual application, allowing continuous production without interruptions.

4. Safety:

   • Reduced manual handling of lubricants improves workplace safety.

Types of In-Die Automatic Lubrication Systems

1. Spray Systems:

   • Airless Spray: These systems use hydraulic pressure to atomize lubricant into fine droplets, ensuring precise application. Ideal for high-speed presses.
   • Air-Mixed Spray: Combines lubricant with compressed air for controlled dispersion. Suitable for various applications.
   • Mist Systems: Deliver a mist of lubricant particles, providing even coverage.

2. Roller Systems:

   • Roller Lubricators: Rollers apply lubricant directly to the sheet metal surface as it enters the die. Effective for continuous strip feeding.
   • Brush Roller Systems: Brushes evenly distribute lubricant across the metal surface.

3. Pad Systems:

   • Felt Pads: These absorbent pads hold lubricant and transfer it to the metal during each stroke. Simple and reliable.
   • Sponge Pads: Similar to felt pads but use a sponge-like material for controlled lubricant release.

4. Wick Systems:

   • Wick Feeders: Wick-based systems draw lubricant from a reservoir and deliver it through capillary action. Suitable for low-volume applications.

Choosing the Right IN-DIE Lubrication System for Your Equipment

Consider the following factors:

1. Application Type:

   • High-speed presses require precise spray systems.
   • Roller systems work well for continuous strip feeding.
   • Pad or wick systems suit slower presses.

2. Lubricant Type:

   • Choose a system compatible with your lubricant (oil, grease, or dry film).
   • Consider viscosity, additives, and environmental impact.

3. Die Design and Geometry:

   • Evaluate the die layout, part complexity, and access points for lubrication.
   • Ensure the system reaches critical areas.

4. Maintenance and Refilling:

   • Opt for systems that allow easy refilling during operation.
   • Consider maintenance intervals and ease of cleaning.

5. Budget and ROI:

   • Balance initial investment with long-term benefits.
   • Calculate savings from reduced downtime and improved part quality.

What Is Coil Stock Lubrication?

Coil stock lubrication ensures proper lubrication of metal coils (sheets or strips) before they enter the die. It’s essential for efficient stamping processes.

Why Is It Important?

• Die Protection: Lubricated coils prevent galling and scoring on dies.
• Consistent Lubrication: Evenly coated coils lead to better part quality.
• Reduced Friction: Lubricated stock reduces wear and heat during forming.

Types of Coil Stock Lubrication Systems:

1. Roller Lubricators:

   • Evenly coat the material (top and bottom) before it enters the press.
   • Reliable and widely used for stock lubrication.

2. Spray Cabinets:

   • Ideal for lubricating the top and bottom of coil stock.
   • Adjustable spray nozzles for precise application.
   • Some systems recycle run-off lubricant.

Automatic In-Die Lubrication Versus Coil Stock Lubrication

What is better, in-die lubrication or coil lubrication? Or should you use both?

Both in-die lubrication and coil stock lubrication serve essential purposes, and the choice depends on your specific production needs:

1. In-Die Lubrication:

   • Advantages:
     • Precise application directly within the stamping die.
     • Minimizes wear, friction, and heat during metal forming.
     • Enhances part quality and extends die life.
   • Ideal For:
     • High-speed presses.
     • Applications requiring controlled lubrication.
   • Considerations:
     • Consumes more lubricant than coil stock systems.

2. Coil Stock Lubrication:

   • Advantages:
     • Lubricates the entire coil before it enters the press.
     • Ensures consistent coverage across the entire sheet or strip.
     • Reduces defects and improves part quality.
   • Ideal For:
     • Continuous strip feeding.
     • Efficient stamping processes.
   • Considerations:
     • May not provide precise point-to-point lubrication.

3. Using Both:

• • Combining both methods can be beneficial:
    • Pre-Lubrication: Coil stock lubrication prepares the material.
    • In-Die Lubrication: Ensures precise lubrication during forming.

Choosing the Best System

Consider your specific process, lubricant type, and budget. Roller lubricators provide complete control, while spray cabinets offer targeted lubrication where needed.

Contact PRI to have one of our expert application engineers consult with you to help you choose the best in-die automatic lubrication and/or coil lubrication systems for your equipment and specific production needs.
 

Pax Products Lubrication Systems

PAX automatic In-Die Lubrication Systems

As we just learned, in-die automatic lubrication systems are designed to apply lubricant precisely within a stamping die during metal forming processes. These systems ensure that moving parts, such as punches, dies, and slides, receive the right amount of lubrication at the right time. They play a crucial role in dissipating heat, reducing friction, prolonging die life, and minimizing downtime from press room equipment failure.

• Reduction of Die Lubricant Usage – Precisely applying the proper amount of die lubricant cuts waste and saves money.
• Higher Productivity – Proper lubrication increases run time.
• Improved Piece Part Quality – Proper lubrication reduces stress on parts being fabricated; thus, quality is greatly improved while scrap rates are reduced!
• Faster Press Speeds – By reducing heat, the Pax system permits increased press speeds which results in higher profits.
• Better Housekeeping – A clean environment improves worker’s attitudes. The Pax system insures that die lubricant is applied only to critical areas – not the side of the press, the feeder, or floor.
• Labor Savings – Eliminates inefficient manual application of lubricants with brushes or spray bottles.

Pax Products offers two main in-die lubrication systems:

1. Pre-Pressurized Systems

   • Available in 5, 15, and 30-gallon capacities.
   • Precise synchronization during the press stroke.
   • Supports 1 to 14 pumps depending on the model.

2. V-Series Systems

   • Independently programmable spray lines.
   • Suitable for various viscosities.
   • Available with or without a reservoir and control.

PAX Pre-Pressurized Systems

When comparing the Pre-Pressurized System by Pax Products to other lubrication methods, it’s essential to consider various approaches. Here are some common lubrication methods and their characteristics:

1. Grease Lubrication: Grease is packed into bearings, gears, or components, acting as a barrier against friction and wear. It’s suitable for applications where oil lubrication is impractical, such as vertical shafts or high temperatures.
2. Oil Lubrication: Continuous or periodic supply of oil to moving parts. Ideal for high-speed machinery, with methods like splash lubrication, circulating oil systems, and oil mist systems.
3. Dry Lubrication: Uses solid film lubricants or PTFE coatings to reduce friction without liquid lubricants. Common in industries where cleanliness is crucial, such as food processing.
4. Air Lubrication: Specialized method in marine and shipping industries. Compressed air creates a layer of bubbles beneath vessels, reducing hull-to-water friction, improving fuel efficiency, and minimizing environmental impact.
5. Solid Lubrication: Graphite or molybdenum disulfide coatings between sliding surfaces. Resistant to extreme pressures and temperatures, often used in aerospace and automotive components.

Each method has its advantages and limitations. To choose the right lubrication method for your equipment, assess factors like machinery type, operating conditions, and manufacturer recommendations.

Pre-Pressurized Lubrication Systems Overview

• Pre-Pressurized Lubrication Systems use a diaphragm pump to deliver a steady supply of pressurized lubricant to each distribution pump. These pumps operate with air-driven pistons at a 10:1 air-to-lubricant pressure ratio.
• Each cycle of the distribution pump pressurizes a specific volume of fluid, based on the pump's setting, and sprays it onto the die or stock material. Importantly, the air used does not mix with the lubricant.
• Each spray line has its own dedicated distribution pump, allowing for precise volume adjustments and ensuring consistent lubricant delivery with every spray.
• Standard Pax distribution pumps can be adjusted to spray between 0.0023 and 0.0210 fluid ounces (0.068 to 0.621 cc) per cycle, with high-volume options available.
• Available in  2 gal, 5 gal, 15, and 30 gallon reservoirs.

Benefits of PAX's Pre-Pressurized Lubrication systemS:

Pax's innovative Pre-Pressurized System was originally designed in 1975 to optimize lubrication efficiency for stamping and other industrial applications. Its key features include:

1. Increased Efficiency: By applying lubricant only where and when needed, Pax customers experience increased production speeds, decreased lube consumption, and improved part quality.
2. Airless Spray: The system uses an “airless” spray, which enhances adhesion to materials and reduces airborne lube compared to air-mixed sprays.
3. Refill While Operating: You can refill the system while it’s in operation.
4. Lubrication Recycling: The system is arranged to promote lubrication recycling.
5. Custom Configurations: Pax offers various models with reservoirs, tankless options, and dual solenoid & dual lube systems.
6. Economical: The system can spray both thin and thick lubricants, and it can be configured with or without a reservoir, dual lube applications, and cycle frequency controls.

Versatility in Lubricant Viscosity

• The system's 10:1 air-to-lubricant pressure ratio enables it to spray both low and high-viscosity lubricants.
• For fluids with viscosities above 300 SUS, consulting with PRI is recommended to ensure proper system, nozzle, and spray line configuration.

Standard Control Features

The Pax Pre-Pressurized system includes a PCB membrane switch with standard functions:

• Hand Cycle Button: Manually cycles the unit (located in the lower right corner of the keypad).
• Low-Level Indicator Light: Activated if the unit has a low-level float (located in the upper left corner of the keypad).

Optional advanced controls offer additional functionalities.
 

Pax Pre-Pressurized Models

Below is an overview of the available PAX pre-pressurized in-die lube systems.  For complete model options and details, along with system options and fittings, contact PRI to speak with one of our application engineers.

Models with Reservoirs

Tankless Models

Pax tankless systems can be utilized with central lubrication supply systems or to spray lubrication directly out of the drum or other reservoirs

Tankless systems require require either a supply pump and filter assembly or a barrel mount supply pump assembly (examples shown below).

Dual Solenoid & Dual Lube Systems

Multiple solenoid systems:

• Provide the ability to independently cycle different banks of distribution pumps.
• This is applicable for transfer and long-feed progression applications when a certain number of pumps need to be cycled multiple times or at varying times throughout the stroke.
• In cases where even greater control flexibility is required, Pax’s V-Series system should be considered.

Dual Lube Systems:

• Dual lube systems allow selection between two different lubricants, stored in separate reservoirs
• Dual, pre-pressurized systems can use either a 6T, 10T, or 14T tankless system or a 6-6T, dual solenoid, tankless system in conjunction with any of Pax’s standard reservoirs.
• Lube selection, which reservoir the system will draw from, can be done via either manual or electronic valves.

Pax V-series Lubrication System

V-Series System Overview

• Airless Spray Technology: No air mixed with lubricant, resulting in better adherence to material and reduced airborne lubrication.
• Fluid Viscosity Adaptability: Adjustable air pressure for handling fluids of various viscosities; consultation with PRI is recommended for fluids over 100 SUS.
• Programmable Spray Lines: Each solenoid valve is independently programmable for different spray intervals and durations (minimum 20 milliseconds).
• No Priming Issues: A large diaphragm pump delivers filtered fluid to spray lines at pressures up to 100 psi.
• Low Maintenance: Requires no airline lubrication, dynamic seals, or accumulators.
• Available in 5,15, and 30 gallons

Key Features:

• Programmable Spray Lines: Independently controlled spray lines for precise lubrication application.
• Versatile Lubricant Handling: Suitable for lubricants up to 100 SUS, including water-soluble types mixed in a 3:1 water to lubricant ratio.
• Custom Configurations: Available with or without a reservoir and control, and can be configured for dual lubricant applications.

Benefits:

• Reduced Lubricant Usage: Precise application and recirculation of excess lubricant can cut lubricant usage by over 50%.
• Enhanced Production and Tooling Life: Proper lubrication minimizes heat and friction, extending tooling life and enabling higher production speeds with better part quality.
• Improved Working Conditions: Targeted application of lubricant keeps the environment clean, improving worker morale by preventing mess on the press, feeder, and floor.

Pax V-series Lubrication System Models

V-Series Models with Reservoirs

V-Series Tankless Models

• Pax tankless systems can be utilized with central lubrication supply systems or to spray lubrication directly out of the drum or other customer-supplied reservoirs.
• Depending on the application, the tankless units can be provided with the optional diaphragm supply pump and an optional filter assemblies
• Alternatively, units can be supplied without a pump or filter assembly for central lubrication systems

V-Series Dual Lube Systems

• Dual lube systems allow users to store and select between two different lubricants in separate reservoirs.
• Lube selection, which reservoir the system will draw from, can be done via either manual or electronic valves.
• Dual systems utilize either a V5T, V10T, or V15T tankless system in conjunction with any of Pax’s standard reservoirs.

Pax CoIl Stock Lubrication spray cabinets

• Pax spray cabinets are ideal for lubricating the top and bottom of coil stock as it enters the die, eliminating the need for cumbersome and maintenance intensive roller systems.
• Features include adjustable spray nozzles, as well as a system designed to recycle run-off lubricant.
• Pax spray cabinets are compatible with all Pax lubrication systems.

How Pax SPray Cabinet Lubrication works:

• Sprays, Contains, and Collects Lubricant:
• Non-Contact Lubrication
• Typically attached to and adjustable with roll feeder

Pax Spray Cabinet Models

For more information on our collection of Pax Products, please visit the following links on the Pax Website ( links open in new tab):

• Pre-Pressurized Systems
• V-Series Systems
• Rollers, Cabinets, & In Die Lube