Formulation of polymer-based lubricant for metal forming

Abstract A new metal forming lubricant based on polymeric materials has been developed. The lubricant has been developed through emulsion copolymerization. Copolymers with the common composition of stearyl methacrylate and 2-hydroxyethyl methacrylate acid phosphate were made with three secondary polymers: methyl methacrylate, butyl acrylate, and 2-hydroxyethyl methacrylate. The performance of the developed lubricant was evaluated using the ring compression and twist compression tests. The performance of the polymeric lubricant was compared against a zinc-phosphate-coating-based lubricant, commonly used in forging, and three other commercial lubricants. The polymeric lubricant exhibited at least equal performance in all tests conducted at room temperature. Preliminary test results show that the developed lubricant can be used effectively for non-severe deformation processes such as cold heading and extrusion processes with low surface expansions.

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