treinamento lubrificantes

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CMB/Sept 2000 Treinamento Lubrificantes Post lubricants Cupper Emulsions Cupper neat oil applied using HST’s Appli coater™ Bodymaker lubricants

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Treinamento de lubrificação

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Page 1: Treinamento Lubrificantes

CMB/Sept 2000

Treinamento Lubrificantes

•Post lubricants

•Cupper Emulsions

•Cupper neat oil applied using HST’s Appli coater™

•Bodymaker lubricants

Page 2: Treinamento Lubrificantes

CMB/Sept 2000

Tipos de lubrificação

Page 3: Treinamento Lubrificantes

CMB/Sept 2000

aceite

agua

emulsión

Formación de Formación de Emulsiones Emulsiones

con los Tensiactivoscon los Tensiactivos

Page 4: Treinamento Lubrificantes

CMB/Sept 2000

Emulsión W/O

(agua en aceite)

Emulsión O/W

(aceite en agua)

TTipos de emulsionesipos de emulsiones

Page 5: Treinamento Lubrificantes

CMB/Sept 2000

Burbuja de espuma

Moléculas de tensiactivo

Fase acuosa Fase gaseosa (aire)

Page 6: Treinamento Lubrificantes

CMB/Sept 2000

Post (ou Pre-lube) Lubricant Funções

• Garante a base de lubrificação para a fabricação da lata e completa a lubrificação da cupper.

• Melhora a molhabilidade da bobina ( para aplicação de óleo de copo).

• Protege a superfície da bobina contra manchas de água e oxidações.

• Reduz os arranhões produzidos pelo transportes das bobinas.

• Dispersa as sujidades provenientes do processo de laminação

• É aplicado por energia eletroestática e se molda ao requisitos do fabricante de alumínio.

Page 7: Treinamento Lubrificantes

CMB/Sept 2000

Lubrificante de CoposFunções

Reduz o atrito entre a superfície do alumínio e o corpo da ferramente, pela lubrificação hidrodinâmica.

Promove a base de lubrificação para fabricação da lata na body maker

Garante a lubrificação necessária para expulsar a lata do punção no final do processo de estiramento

Aumenta o controle na processo de formação do copo, sem rugas, o que diminui a incidência de blush.

Promove uma proteção extra contra corrosão do ferramental pela presença de inibidores de corrosão no óleo.

Page 8: Treinamento Lubrificantes

CMB/Sept 2000

Cupper & Post (or Pre-lube) Lubricant classification

• Semi-Synthetic Emulsion Based– Mineral Oil– Synthetic Ester– Fatty Acid Amine Soap– Non-ionic Emulsifiers– Corrosion Inhibitors

• Semi-Synthetic Non-Emulsion Based (APPLI-COATER™)– Mineral Oil– Synthetic Ester– Fatty Acid– Corrosion Inhibitors

Page 9: Treinamento Lubrificantes

CMB/Sept 2000

Tipos de Post Lubes

• DTI 5600-PL– Um dos primeiros a serem desenvolvidos. É o utilizado no Brasil

• DTI 5600-PLE

• DTI 5600-PLR

• DTI 6000 CPL é o lançamento mais recente e supera todos os anteriores e está sendo introduzido no Brasil por apresentar melhores caracteristicas para climas como o do Brasil

Page 10: Treinamento Lubrificantes

CMB/Sept 2000

Appli-Coater™ instalação

Page 11: Treinamento Lubrificantes

CMB/Sept 2000

Parametros Lubrificantes de copos emulsão

DTI-M3, M3B and C1 cupping lubricants

Concentration 20-40% (dependant on Durometer of rollers)

Cup Weights 20–25mgrms/cup (33cl)25-30mgrms/cup (50cl)

Biocide M3B - bio-stableM3/C1- 1000 – 1200ppm

PH 8.0-8.8Bacteria <10³Fungus <10Pre-mix conc As required to maintain cupper

concentration

Page 12: Treinamento Lubrificantes

CMB/Sept 2000

Products for AluminumCupper Lubricants

• DTI M3A com buffer de biocida pode ser considerado bioestático

• DTI C1 Cupper– Melhora aparência da lata, latas mais claras e maior brilho, melhor

performance ( reduz short can)

• DTI SNL-2 Cupper Applicação Neat applicoater.Ultimo desenvolvimento reduz significativamente o TOR, latas com interior claro, latas mais brilhantes.

• CL 300B – Neat oil usado no applicoater não é bioestático• CL 400 -- Neat oil usado no applicoater não é bioestático.

Page 13: Treinamento Lubrificantes

CMB/Sept 2000

ParametrosÓleo integral

• DTI-C1 applied as a neat cupping oil using HST Appli-coater™

Concentration Not applicable

Cup weights 20-25mgrms/cup (33cl)

25-30mgrms/cup (50cl)

Biocide Not required

Bacteria/fungus No check required

Pre-mix Not required

Page 14: Treinamento Lubrificantes

CMB/Sept 2000

ParametrosÓleo integral

• CL300 B – Aplicação integral no applicoater

Concentração Não aplicável

Cup weights 18-25mgrms/cup (12 oz)25-30mgrms/cup (16 oz)

Biocide Não necessárioBacteria/fungus Não requer checagemPre-mix Não requerido

Page 15: Treinamento Lubrificantes

CMB/Sept 2000

Filter system

Page 16: Treinamento Lubrificantes

CMB/Sept 2000

Troubleshooting lube parameters

• Cupper parameters1. General comments

2. Emulsions

3. Appli-coater neat oils

• Bodymaker parameters1. General comments2. pH control3. Concentration4. Tramp5. Cup and post lube6. Bacteria7. Water hardness8. Aluminium9. Temperature10. Coolant flow11. Foam

Page 17: Treinamento Lubrificantes

CMB/Sept 2000

Coolant e suas Funções

• Boundary Lubricant Function – complementa a lubrificação feita no copo.– Garante bom acabamento da superfície da lata– reduz o atrito entre o alumínio e as ferramentas reduzindo assim os

short cans, marcas de estiramento e desplacamento– Promove detergência necessária para efetuar a limpeza das

ferrametas, limpar o alumínio incrustado, e facilita a limpeza da lata na lavadora

– Protege as ferramentas e o equipamento contra corrosão/oxidação– Refrigera o ferramental– Cuida do tramp oil limpando e dispersando dentro do coolant. Não

o deixa dentro da máquina

• Coolant / Detergent Function

Page 18: Treinamento Lubrificantes

CMB/Sept 2000

Parameters Bodymaker lubricants

• WBLF Bodymaker lubricant (standard technology since 1991)Concentration 2.0 – 2.5%pH 8.8 – 9.1 9.2 – 9.4Tramp 0.5-2.0%Cupper oil 0.5-1.5%Biocide 1000 – 1500ppm Bacteria/Fungus <10³/<10 Temperature 42 – 46°CFlow rate 65 – 75litres/minuteWater quality <50ppm

• TRLEX bodymaker lubricant (first generation bio-stable lubricant containing no biocide)

Concentration 2.0 – 2.5%pH 9.2 – 9.4Tramp 0.5-2.0%Cupper oil 0.5-1.5%Biocide Triazine may be added if required to maximum 500ppm Bacteria/Fungus <10³/<10Temperature 42-45°CFlow rate 65 – 75litres/minuteWater quality <50ppm

Page 19: Treinamento Lubrificantes

CMB/Sept 2000

O que é tramp oil ?

• Tramp = Tudo o que não é coolant

( óleo de copo, óleo mineral, finos de alumínio,

sabões, graxa, cinzas, e outras impurezas)

• O tramp é medido em % dentro do sistema de óleo solúvel.

• Lubrificantes DTI analisam o tramp bom ( o óleo de copo)

Page 20: Treinamento Lubrificantes

CMB/Sept 2000

Geração do tramp ruim no sistema de óleo solúvel

Page 21: Treinamento Lubrificantes

CMB/Sept 2000

Yolk Slide

Ram

Ram Spacer

Locking Collar

SUBCONJUNTOSRam To Yolk

Page 22: Treinamento Lubrificantes

CMB/Sept 2000

Bucha primária

Bucha secundária

8 Lee-Jets

Haste do punção

Entrada de óleo

Primary and Secondary Bushing

SUBCONJUNTOS

Page 23: Treinamento Lubrificantes

CMB/Sept 2000

O fluxo do Coolant é de 26 GPM / 120 lPM Temperatura de 40ºC

O óleo solúvel refrigera e limpa o ferramental removendo parte . do óxido de alumínio dando maior durabilidade ao processo !!!

Soluble Oil Function

LUBRIFICAÇÃO

Page 24: Treinamento Lubrificantes

CMB/Sept 2000

Soluble Oil Function

LUBRIFICAÇÃO

Algumas máquinas possuem medidores de vazão diferentes e termômetros acoplados. Além de medir ele também monitora se há fluxo mínimo.

Page 25: Treinamento Lubrificantes

CMB/Sept 2000

Estas características devem ser acompanhadas a cada turno , pois problemas podem surgir na lata como, blush, meia-lata e bleed through.

Soluble Oil

LUBRIFICAÇÃO

Page 26: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (1) Coolant parameters

• General comments– Making the coolant captive (leak free)

• Maintaining a high level of cupper lubricant helps bodymaker performance

• Tramp is important to remove aluminium fines, but too much can create their own problems

• Water quality of low hardness is needed to prevent sludge build up and keep detergency in the coolant

• Keeping consistent coolant parameters helps maintain continuity in the process

• Captive trench reclaim systems always challenge the pH and the bacteria free coolant system

• TRLEX will require some support from either Buffer ‘B’, or biocide to prevent bacteria

Page 27: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (2) Coolant pH

• Coolant pH is affected and determined by– Concentration of product

– Age of coolant (how captive the coolant is)

– Amount of cupper lubricant in the coolant

– Biocide

– Buffer ‘B’

– Bacteria activity

– Contamination

– Water quality/hardness

Page 28: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (2a) pH control

Cause Line issues SolutionLow pH due to bacteria activity

•Can Scoring and tear-offs•High tooling usage •Difficulty in testing concentration•Bad egg smell•Health issues-dermatitis•Tooling leaching and ‘pin holes’•High filter usage•Conveyor bio build up

•Switch off trench reclaim•Find the source of the problem•Clean and sterilise the problem area•Set the AMU concentration high•Do not rely on concentration check•Add biocide to main system to 1500ppm or a Kathon dose if allowed at 200ppm•Correct pH by addition of Buffer ‘B’

Low pH due to washer contamination or floor soaps

•Can scoring and tear-offs•Tooling usage•Difficulty in testing coolant•Encouraged bacteria activity

•Coolant analysis may be required to find cause –Sulphates/fluorides•Find the source of the contamination – washer infeed (overspray)•Partial dump may be required•Correction of the pH by adding Buffer ‘B’

High pH caused by biocide

High pH caused by caustic

•Health issues•Possible stripping/rollback issues

Check biocide ppm and correct

Check DI regeneration leaks

Partial dump may be needed if severe

Page 29: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker(3) Concentration (WBLF/TRLEX)

• Coolant concentration is determined by either:– Titration

• Advantage – Quick and easy to read titration value and make calculate

• Disadvantage – Heavily influenced by biocide and Buffer ‘B’

– Polymer• Advantage – Not affected as much by

biocide and buffer ‘B’• Disadvantage – Water soluable part of

the Cupper lubricant affects readings

Note:• The preferred test method for TRLEX is

titration and for WBLF polymer

• Titration– Buffer ‘B’ (1000ppm) = 5mls– Triazine (1000ppm) = 3mls – C1 (1%) = 1mls– M3/5000NCL (1%) =0.8mls

• Polymer– C1 (1%) = 0.6– M3/5000NCL = 0.3– Buffer ‘B’ (1000) = 0.1– Triazine (1000) = 0.1

Page 30: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (3a) Coolant concentration

Cause Line issues Solution

High concentration •High applied cost

•Possible that the cup lube is washed off creating scoring

•Correct concentration

Low concentration •Can scoring –lack of boundary lubricant

•Build-up on the tooling-lack of detergency

•Corrosion-Lack of corrosion inhibitor

•Out of round cans-due to tooling build-up

•Out of spec sidewall-due to excessive tooling wear/build-up

•Correct concentration

Page 31: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (4) Tramp control

• Tramp contamination (hydraulic oil)– Some tramp is normal ( >0.8%) and does help to remove Aluminium

– Too much tramp can cause their own problems (>2.0%)

– Maintaining an acceptable tramp is a balance between fixing the hydraulic leaks and a maintaining a reasonable captive coolant system

– The bodymaker seal pack is usually the main cause of leaks

– Changing the seal pack will not be successful if the ‘ram’ is scored, or worn at the limits of its travel

– Seal pack air vent needs to be working- they reduce leaks and help troubleshoot bad leaks

– Redraw carriage push rod seals are next in priority, again bushes and push rods need to be in good condition

– Exterior bodymaker leaks from the HP system are easily seen

– Following the individual bodymaker hydraulic oil consumption does help

– Trench reclaim will capture the hydraulic leaks and increase tramp

– Polymer could be used but as a last option

Page 32: Treinamento Lubrificantes

CMB/Sept 2000

Standun and CMB bodymaker hydraulic oil control

Page 33: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (4a) Tramp

Cause Line issues Solution

High tramp in the coolant caused by leaks from the bodymakers

•Pro-active control over the bodymaker hydraulic oil consumption is the best answer

•Can cleaning issues•Sludge build up•Tooling polishing and high usage•Oval cans and scratching•‘Sugarscoops’•Stripping and rollback problems

•Identify the problem bodymakers and fix them•If serious stop trench reclaim •Ensure skimmer and coalescer are working efficiently•Large coolant settling tanks help•Additional trench recovery system benefit from an additional coalescer

Low tramp in the coolant- Lack of mechanical protection

•Mechanical contact wear possible•Slow long stroke bodymakers more prone •Punch and ring damage will follow

•Allow tramp to increase•Reduce, or switch off skimmers and colescers

Page 34: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker Coolant (5) Cup and post lubricant

• Very desirable in the coolant system – Additional good can making material

– Provides additional hydrodynamic lubrication to protect against mechanical contact of punch and rings

– Provides additional emulsifiers to the coolant

– Helps keep tooling interface clean

• Easy to measure by refractive index– Poor systems 0-0.3% (Coolant not captive and probable low cup film weight)

– Good system 0.6-1%

– Ideal systems 1-2%

Page 35: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (6) Bacteria issues

• Lubricants are blended from molecules that bacteria derive foodstuffs

• Bacteria destroys the emulsifiers, fatty acids and corrosive inhibitors in the coolant

• They reduces the system pH by emitting organic acids as part of their active metabolism

• Causes stickiness resulting in can scoring, T/O and stripping problems

• Causes problems in determining concentration

• Causes frequent coolant filter changes

• Attacks the tooling– Reducing system pH

– Localised drop in pH

– Destroys the corrosion inhibitor in the coolant

• Health issues – Most human pathogens are only active at pH 7.45

– Breaks in the skin allow bacteria access. The excretion of metabolic acids triggers histamines which then causes itching and redness

Page 36: Treinamento Lubrificantes

CMB/Sept 2000

Bio-organisms

Algae

Mold

Fungi

Bacteria

Page 37: Treinamento Lubrificantes

CMB/Sept 2000

HMB vs. Dip slide cultures

• HMB test for the metabolic activity of the bacteria –method is Bio-chemical

• Measurement is by the bacteria enzyme being produced• Measurement therefore tells us how active the bacteria is • The HMB measurement tells us how much ‘eating’ and

degradation of the coolant is taking place by the bacteria• Advantage is an immediate result

• Dip slides, or cultures- method is growth• Measurement is by using a nutrient and incubation• Number of colonies gives an estimation of concentration, or

number of bacteria in the system

• The two methods do not necessarily always correlate

Page 38: Treinamento Lubrificantes

CMB/Sept 2000

Controlling Microbial build up

• Be pro-active by monitoring biocide usage

• Cupper and coolant system measurement– pH measurement

– Coolant biocide measurement

– Bio-cultures/ HMB

• Audit potential problem equipment– Trenches and can conveyors are prone to grow bacteria

– Keeping control of the trenches and conveyors actual reduces biocide usage

• Bacteria correction program– Find the source of the problem and fix it by cleaning and sterilising

Page 39: Treinamento Lubrificantes

CMB/Sept 2000

(7) Harmful hardness ionsfrom water

• Calcium and Magnesium.• Starts to form sludge above 50 ppm (aluminium soaps)• Acceptable limit usually at 120 ppm• If softener is exchanging large amounts of sodium ions the system can run up

to 200 ppm• Captive system produce higher ppm readings• High coolant temperatures and summer periods produce an increase in ppm

level

• Silica (10ppm) form abrasive build up• Chloride and Sulphate corrosive to steel and carbide

• Acceptable is 30-50ppm• Requires close monitoring 50-100ppm• Potential problems >100ppm

Page 40: Treinamento Lubrificantes

CMB/Sept 2000

Controlling hard water ions in the coolant system

• Maintain the water softener• Check outgoing water quality (< 50ppm)• Check regeneration cycle and salt usage• Exchange of sodium ions adds extra detergency to the coolant

• Monitor FE cleandown water• High usage of wash down water• Maintenance days are prone to give problems

• Trench recovery systems require more attention• Captive coolant systems will result in higher levels of hard water salts

• Watch summer water table and for water supply changes

• High coolant temperatures evaporate and concentrate the salts• High coolant temperatures can mean 10-20% more water input to the coolant system • Summer months may need another 10-20% more water

Page 41: Treinamento Lubrificantes

CMB/Sept 2000

(8) Sources of aluminium finesin the coolant system

• Coil substrate generated during the rolling process – Amount of aluminium debris can differ from each Coil suppliers

– Coil slitters do generate high amounts of aluminium debris

– Range of micron aluminium debris can range from as low as 0.1µ and up to 30µ

• Cup manufacturing– Poor lubrication or worn tooling will generate more debris

• Bodymaker redraw re-forming– Poor cup quality, worn tooling and lack of cup lubricant

• Ironing operation– Poor coolant control and worn tooling

Page 42: Treinamento Lubrificantes

CMB/Sept 2000

Controlling the build upof Aluminium fines

• Adequate filtration– Filtration is a trade-off between cost and filtration– A higher performance filter media will improve situation– Mechanical condition of filter (leaking, or poor controlled CV

valves)• Floatation and removal of the tramp

– Does help reduce the level of aluminium fines• Trench recovery systems (closed systems) require more attention• Worn tooling generates more aluminium debris• Poor, or inadequate lubrication in the cupper• Poor, of inadequate lubrication in the bodymaker • TRLEX will hold more aluminium due to its alkalinity and amine• Centrifuge can help • Polymer will remove aluminium with the tramp

Page 43: Treinamento Lubrificantes

CMB/Sept 2000

(9) Coolant temperature

Cause Line issues SolutionLow coolant temperature

Usually below 38°C

•Short cans (too short to trim)

•Tear-offs-(due to lack of wetting)

•Can scoring

•Poor stripping

•Tooling build-up

•Out of round cans

•Poor trimming

Adjust temperature to specification

High coolant temperature

Usually above 48°C

•Long cans Adjust temperature to specification

Page 44: Treinamento Lubrificantes

CMB/Sept 2000

(10) Bodymaker coolant flow rate

• High flow rates > 100 litres/min– Cup infeed flutter– Can flutter at the discharge– Short can length and trimmer jams

• Low flow rates < 50 litres/min– Heat build up– Long cans– Build-up on tooling

• Can scoring• Tear-offs• Out of round cans

• General recommendation is 65-75 litres/min

Page 45: Treinamento Lubrificantes

CMB/Sept 2000

(11) Foam causes and prevention

• Product choice – Modern synthetic lubes cause problems

– Usually there is low foam version available

• Soft water– Soft water provides more detergency by the

exchange of sodium ions. The harder the area water the more sodium ions

– If foaming problems are bad some hard water could be added

• Bodymaker coolant flow – High flow are the major cause of foam

– Griswold valves are recommended

• Coolant supply pressure– High pressures agitate the coolant

– Pumps that leak coolant also draw in air that creates foam

• Toolpack spacer design– Alperton type restrict the flow and

agitate the coolant

• Product input rate– Fresh product input brings more detergency

to the system

• Foam traps– Liquid levels above outlets

– Bodymaker outlet pipes too small, or that go uphill

• Defoamer additions– Best place to add the defoamer is where the

foam is being generated

• Dirt loading– Tramp dirt and aluminium all help to

suppress foam

Page 46: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker(7) Out of round cans

• Coolant Parameters out of specification – Temperature too low (44°C nominal)– Tramp oil too high

• Over 3% may result in problems• High speed bodymaker are more sensitive to high tramp

– Low concentration of bodymaker coolant– Coolant low flow, or restricted

• Build up on punch, or rings– Check cup lubricant is sufficient– Check aluminium debris on cups

• Bodymaker misalignment– Punch to toolpack– Redraw sleeve alignment/pressure or overtravel– Cup locator/infeed

Page 47: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker(8) Bleedthrough

• Most bleedthrough problems are generated in the cupper, or at the bodymaker redraw

– Worn or badly matched cupper tooling– Bodymaker redraw sleeve or redraw ring condition

• Coil substrate and lubrication are also factors• Following the generally troubleshooting rules will identify the source

– Grain orientation– Cup ID– Bodymaker ID and orientation

• Washer etching helps marginally• Lubrication

– Check for low cup weight– High coolant pH– Sludge build up in cupper/bodymaker tooling– Dirt loading high– Dry coils (poor postlube coverage)

Page 48: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker(10) Excessive bodymaker tool wear

• Lubricant– Cupper lubricant low film weight/concentration– Coolant parameters

• Concentration• Ph and bacteria• Tramp %• Cupper %

• Excessive organic build-up on rings– Water quality and coolant sludge– Test aluminium/dirt levels– Check filter cycles and filter media

• Chemical corrosion of tool surface– Check pH and bio activity

Page 49: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker (11) Poor stripping (rollback)

• Oxide, or sludge build up on punch• Score or wear on the punch• Punch too smooth (>6µ finish recommended)• Crosshatching is recommended (1200 grit is normal)• Worn of poor stripper alignment• Air strip too low (10psi bleed air recommended)• Coil substrate• Lowering the coolant flow may help• Low (or high) cup film weights• Coolant parameters out of specification

– Temperature low, or fluctuation– High tramp– pH of coolant

• Too high and the coolant is too stable• Too low and coolant becomes unstable (lack of detergency)

Page 50: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker(12) Sludge build-up in the coolant system

• High water hardness – Minimum incoming water hardness <50ppm– Minimum coolant hardness <120ppm

• Excessive dirt/fines, or rolling oil on coil surface• Coolant parameters

– High tramp oil– Low concentration– Bacteria/fungal activity– Low pH (lack of detergency)

• Insufficient coolant supply to bodymakers• Bodymaker dirt load

Page 51: Treinamento Lubrificantes

CMB/Sept 2000

Bodymaker(13) Can scoring

• Poor coil strip– Heavy oxide deposits

– Aluminium fines/ slivers,

– Dirt (smut)

– Rolled in laminations

• Poor cup quality– Earring

– Wrinkles

– Scored cups

• Cupper lubricant parameters– Low pH (bacteria activity)

– Low film weight

• Coolant parameters– Low pH/bacteria activity (lack of

detergency)

– Low concentration

– Low coolant flow

– High tramp

– Temperature out of specification

• Worn, or ‘build up’ on bodymaker tooling

– Internal scratch • Redraw sleeve and punch

– External scratch• Redraw/ironing rings and stripper

fingers