How Can Galling Be Eliminated In Stamping Operations?

When galling occurs in a metal stamping operation, it is often first thought that the choice of lubricant is the culprit.  But if we look more closely at the root causes of such failures we can easily see that there are physical changes and requirements at the die face that needs to occur before this phenomena can be eliminated.

In many operations things like plastic bags, cellophanes, even plastic wraps are often used over face of the die and work piece to assist and eliminate this issue. Usually you would use plastic only as a last-resort lubricator, but with tighter and tighter tolerances and less effective lubricants, it's possible you may need it for use in a production pinch. The intention is to introduce a slippery membrane between the tooling and work material to reduce friction and encourage metal flow.

You can use plastic to make more metal flow in specific corners, or on one side as a way to determine the height and location of draw beads or pad pressure in tryout. Some parts require that extra advantage to even run production, and several companies have rigged a simple stand and electric motor to feed a roll of plastic into the die with the material.

It is possible that increasing the efficiency of the lubricant application to the work site can also minimize galling in a localized area. Lubricant application is a technical issue, and every situation will have specific demands and need individual assessment. Just looking at your die is not always enough to know if you are applying lubrication as effectively as possible. For some operations, spraying Metalworking fluids lubricant from outside the die might be a good choice, while others might require application of lubricant directly to the coil or blank. Working with your lubricant supplier as well as your application equipment engineer can assist in locating the ideal setup and application.

The next time galling is an issue- remember that the choice of lubricant is only part of the answer. Understanding the setup and die requirements, along with some industry tested application methods will certainly help in minimizing these occurrences. But like any good solution, the keys are to determine the correct application and experience.

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