Comments on: This week update.

By: J. O.

J. O. — Thu, 19 Jun 2014 19:27:06 +0000

Gardolube RS 5770. In the past, I’ve had good luck with it for heavy high-contact forming. Reduced/eliminated wear on the dies, and in my case kept the surface from being scarred by the die and almost eliminated metal transfer onto the die. I used it in an extreme forming application as a replacement for zinc phosphate and soap. It had no effect on secondary operations such as plating or painting. Greases kept wiping/shearing in my case. The more of this fluid we had in the affected areas, the better it worked. If it’s applied too thin, it can shear or wipe away as well. It worked extraordinarily well when applied to manganese phosphated parts.

Stuff smells terrible, costs a little bit, but a 5 gallon bucket should last you a good long time for this kind of work.

By: Ian

Ian — Mon, 16 Jun 2014 17:52:54 +0000

Thanks, Chris – but the work being shown here is all Chuck’s.

By: Chuck

Chuck — Sun, 08 Jun 2014 01:32:47 +0000

We have tried a variety of lubricants But I am willing to try anything that might help. Thanks

By: John D.

John D. — Sun, 08 Jun 2014 00:12:52 +0000

Think you will need selective lubrication to get the front of the magazine to form, rather than shear, even with the multiple step methodology. NLGI Grade 2 grease with moly makes a good impromptu lubricant if the shearing reoccurs or you encounter wrinkling.

Paint a thin layer on the outside only from the front bend line to the edge of the blank. This will prevent the sheet from sticking to the outer die and promote metal flow in this complex area. We used to describe this kind of forming operation in engine bearing shells as ‘forcing steel to commit an unnatural act’! It is a very difficult stamping operation to undertake without cracks or wrinkles. You will also encounter rapid outside die wear in this area without lubrication.

Wax dissolved in xylene makes a more serious lube, and is still much cheaper than commercial formulations. Oils are too thin and don’t provide adequate protection against adhesive wear.

By: Chris Brosnahan

Chris Brosnahan — Sat, 07 Jun 2014 16:51:58 +0000

Good work, Ian & thanx for the updates…after spending five or so years in the Sikorsky Sheet Metal Shop as a paper-pusher (Production Control) I finally realized (too late) what I wished I learned – a trade in machining/metalworking…I’m always impressed how one can take a block of steel or aluminum and uncover the hidden useful part that is locked inside…As Michaelangelo is rumored to have said…sculpting is easy…you just remove the pieces that don’t look like the ‘final product’….congratulations.

CB in FL