What is an In-Die Automatic Lubrication System?
Unist's Uni-Roller® stock lubricators are the best way to ensure proper lubrication, but when extra stamping lubricant is needed for special die areas, an in-die automatic lubrication system may be needed. Supplemental lubrication from an in-die lubrication system is useful on long progressive dies or aggressive forms/draws requiring more lubricant.
An in-die lubrication system is an automatic spray lubrication system, when a programmable fluid controller is used to control the timing and flow of the lubricant dispensed by the in-die nozzle lubrication system. Unist controllers have the ability to control not only the main roller lubricator, but also the in die spray nozzles. Manufacturers can fine-tune, save, and recall settings for multiple jobs. Easy changeover ensures the right amount of lubricant is always applied when changing jobs.
Types of Spray Lubrication Systems
Low Volume Spray Nozzles
Low volume spray nozzles use compressed air to atomize and spray the lubricant. Air atomized nozzles use less fluid than liquid only nozzles and still get good coverage as the air fans out the lubricant over a larger area. Some may call them LV nozzles or micro mist spray nozzles. An automatic in-die spray system with LV nozzles allows for precise and consistent coverage, allowing for repeatable results over multiple runs.
Unist Low Volume Spray Nozzles don’t drip when shut off and have a fast response time due to the integral fluid shut off valve. They are available with a variety of spray patterns and feature precision adjustments on the nozzle itself or remote adjustments at the controller’s valve stack for when the nozzle is mounted where it is not accessible.
Airless Spray Nozzles
Airless directional spray nozzles, or liquid only nozzles, dispense lubricants using the liquid pressure only. As the fluid flows through a small orifice in the nozzle tip, it creates a spray pattern. This can be thought of like a garden hose spraying through a fan spray nozzle, just on a smaller scale.
An airless spray nozzle consumes more lubricant than an air atomized nozzle. Airless nozzles also can be more prone to clogging, more likely to drip when shut off, and are more limited in the viscosity of the fluid that can be sprayed when compared to low volume spray nozzles. However, they are easy to install and economical when used sparingly.
Low Volume Spray Nozzles vs Airless Spray Nozzles
The decision between airless nozzles and low volume spray nozzles relies more on budget, process, and the lubricant being used than the specific part or tool. The best control will come with a low volume nozzle, however airless spray nozzles can be sufficient for some.
In-Die Nozzle Quick Connect
When in die nozzles are rigidly mounted in the tool, the In-Die Quick Connect manifold allows for easy changeover of dies with a convenient, keyed connection between nozzles and controller in the mist spray unit. Nozzles can be fixed in the die and will not need to be aimed each time a job is set up. This helps stampers achieve consistency in the amount and coverage of lubricants used in die casting, and minimizes change over time.
Why Choose Unist In-Die Lubrication Systems?
Unist stock lubrication systems allow for complete control of stock lubrication. A Uni-Roller system can evenly coat the material, top and bottom, before it goes into the press. A Unist LV nozzle or Airless spray nozzle can provide the extra lubricant when and where needed. A programmable controller such as our SmartFlow™ allows for easy setup, automated job changeover, and process monitoring to ensure the right amount of lubricant is always dispensed. Compared to a full in-die spray system, users can expect to save nearly 50% on lubrication costs with better coverage and less wasted lubricant.