Description:FIELD OF DISCLOSURE
[0001] The present disclosure relates to an automatic die lubrication system for close die multi stage forging.

BACKGROUND OF THE DISCLOSURE
[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Railway wheels are manufactured by either casting or forging process. In forging process, wheel steel is cast in cylindrical moulds in a steel melting shop or by round casters, followed by cutting into blocks having requisite weights as per type of wheel to be manufactured. These blocks are then heated in a rotary hearth furnace for about 1270oC – 1300oC. The blocks, after descaling, are pressed in hydraulic press. Such a hydraulic press can, in an example, include 2 top dies and 3 bottom dies, which are placed horizontally.
[0004] Forging can be carried out in three steps: (i) Upsetting, (ii) Forming and (iii) Punching. Forming process is carried out in closed dies. Die positions and pressing operation are ensured by fixed programmes. Movement of both the top tool frame and bottom sliding table are longitudinal, whereas during upsetting, forming and punching operations, top dies moves in vertical downward direction.
[0005] During upsetting and forming operations, metal flow depends on surface condition of dies and friction between dies and work piece. Earlier die lubrication used to be carried out using Graphite Powder. After completion of upsetting, forming and punching operations, scale used to be removed from the dies by compressed air, and then graphite powder used to be sprayed manually on the dies. Using this method, dies were not lubricated properly, resulting in poor die surface and uneven metal flow due to lack of lubrication.
[0006] There is therefore a need in the art for a system that helps overcome the issues and disadvantages of the prior art mechanisms.
[0007] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0008] In some embodiments, the numbers expressing quantities or dimensions of items, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0009] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[00010] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[00011] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

OBJECTS OF THE INVENTION
[00012] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as listed herein below.
[00013] It is an object of the present disclosure to improve die condition.
[00014] It is an object of the present disclosure to reduce sticker formation (between dies and work piece).
[00015] It is an object of the present disclosure to reduce rejections of wheel during machining stage by introduction of an automatic die lubrication system.

SUMMARY
[00016] The present disclosure relates to an equipment (also interchangeably referred to as component hereinafter) configurable Command and Control Domain Application development framework.
[00017] The present disclosure relates to an automatic die lubrication system (100) comprising: a tank assembly (200) configured to hold a lubricant; a die lubricant spray unit (300) configured to spray said lubricant between one or more dies; and a control unit (400) comprising a Programmable Logic Controller (PLC) for controlling one or more lubrication parameters during spraying of said lubricant between said one or more dies, said one or more parameters being selected from any or a combination of timing, flow, pressure, and concentration during multistage close die forging involving said one or more dies.
[00018] In an aspect, the tank assembly (200) can include a pneumatic pump (204) that is configured to supply said lubricant to spraying headers of each die of said one or more dies based on said one or more controlled lubrication parameters.
[00019] In another aspect, the tank assembly can include a level indicator configured to alert lower level of lubricant in said tank assembly, based on which refilling of said lubricant is done in said tank assembly.
[00020] In another aspect, the control unit (400) can include a Human-Machine Interface (HMI) for centralized monitoring of said spraying.
[00021] In another aspect, the tank assembly (200) can further include any or a combination of a stiffener, and a stirrer 202,
[00022] In another aspect, the die lubricant spray unit (300) can further include any or a combination of a nozzle, a mixing block, a headers, and a hose.
[00023] In another aspect, the system can further include any or a combination of an Electric Resistance Welded (ERW) pipe and a control valve.
[00024] In another aspect, the system can be configured to work in any or a combination of both automatic and as well as manual modes.
[00025] In another aspect, the system can use water soluble graphite (500) as the lubricant.
[00026] In another aspect, working condition for said lubricant can include keeping Block Temperature between the range of 12000C to 12500C, die temperature in the range of 3000-4000C, and operative lubrication concentration to be 10±2%.
[00027] Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like features.
[00028] Within the scope of this application it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

BRIEF DESCRIPTION OF DRAWINGS
[00029] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein:
[00030] FIG. 1 illustrates an exemplary die lubrication system with respect to different components.
[00031] FIG. 2 illustrates exemplary top and side view representations of orientation of dies along with header location.

DETAILED DESCRIPTION
[00032] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[00033] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[00034] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[00035] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[00036] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.
[00037] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating systems and methods embodying this invention. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named element.
[00038] The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth in the appended claims.
[00039] Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits, systems, networks, processes, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[00040] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[00041] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[00042] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[00043] With reference to FIGs. 1 and 2, the present invention relates to an automated die lubrication system. The proposed system is configured to lubricate top and bottom dies of upsetting and forming press. In an exemplary aspect, the proposed automatic system can be configured to clean scales from upsetting and forming dies after completion of forming operation with the help of compressed air, along-with enabling lubrication of top and bottom upsetting dies, and lubrication of top and bottom forming die.
[00044] In an exemplary embodiment, the proposed die lubrication system 100 can be configured to include a tank assembly 200 (having components selected from any or a combination of with stiffener, stirrer 202, pneumatic pump 204, and level indicator ), a die lubricant spray unit 300 (having any or a combination of nozzles, mixing blocks, headers, and hoses), a control unit/panel 400 (having any or a combination of a Programmable Logic Controller (PLC) and Human-Machine Interface (HMI)), Electric Resistance Welded (ERW) pipes, and one or more control valve.
[00045] The present disclosure relates to an automatic die lubrication system (100) comprising: a tank assembly (200) configured to hold a lubricant; a die lubricant spray unit (300) configured to spray said lubricant between one or more dies; and a control unit (400) comprising a Programmable Logic Controller (PLC) for controlling one or more lubrication parameters during spraying of said lubricant between said one or more dies, said one or more parameters being selected from any or a combination of timing, flow, pressure, and concentration during multistage close die forging involving said one or more dies.
[00046] In an aspect, the tank assembly (200) can include a pneumatic pump (204) that is configured to supply said lubricant to spraying headers of each die of said one or more dies based on said one or more controlled lubrication parameters.
[00047] In another aspect, the tank assembly can include a level indicator configured to alert lower level of lubricant in said tank assembly, based on which refilling of said lubricant is done in said tank assembly.
[00048] In another aspect, the control unit (400) can include a Human-Machine Interface (HMI) for centralized monitoring of said spraying.
[00049] In another aspect, the tank assembly (200) can further include any or a combination of a stiffener, and a stirrer 202,
[00050] In another aspect, the die lubricant spray unit (300) can further include any or a combination of a nozzle, a mixing block, a headers, and a hose.
[00051] In another aspect, the system can further include any or a combination of an Electric Resistance Welded (ERW) pipe and a control valve.
[00052] In another aspect, the system can be configured to work in any or a combination of both automatic and as well as manual modes.
[00053] In another aspect, the system can use water soluble graphite (500) as the lubricant.
[00054] In another aspect, working condition for said lubricant can include keeping Block Temperature between the range of 12000C to 12500C, die temperature in the range of 3000-4000C, and operative lubrication concentration to be 10±2%.
[00055] In an aspect, the proposed system 100 can be configured to work in both automatic and as well as manual mode, and can be interfaced with other press equipments. In an exemplary embodiment, the whole system 100 can be configured to be controlled by a control panel having emergency STOP switch. In another exemplary embodiment, the proposed system can be configured to use water soluble graphite 500 as lubricant, wherein in an example, the working condition taken for die lubricant can be such that the Block Temperature is between the range of 12000C to 12500C, die temperature is in the range of 300-4000C, and the operative lubrication concentration is 10±2%. In an exemplary aspect, the lubricants used can be smokeless, odourless, non-toxic water based die lubricants. Lubricant properties can be selected from any or a combination of graphite die lubricant, water based lubricant, odourless lubricant, smokeless lubricant, and non-toxic lubricant.
[00056] In another exemplary aspect, properties of water based die lubricant can be such that the colour is Black, pigment/lubricating solid is High purity micro-graphite, Specific Gravity at 150C is between 1.1 - 1.4, pH Value is in the range of 7.5 - 10.0, Active Solid Contents are 40%±5%, uniform lube film formation on dies is upto 4000C, carrier is water, and Density is between 1000-1200Kg/m3.
[00057] In an exemplary aspect, the proposed lubricant can be sprayed on the dies with the help of suitable cone jet nozzles. The proposed automated system can have a sensor for automatic stopping in the event of mal-functioning of the lubrication system or of the dies or during sticker formation. In the event of mal-functioning, the proposed system, with the help of selector switch lubrication system, can be bypassed for normal press operation.
[00058] In an exemplary aspect, the whole operation of the proposed system can operate in automatic mode and as well as in manual mode. Lubricants can be sprayed after completion of the forming operation. Lubrication process can include removal of scales from the die surface by compressed air, after which, application of the lubricant follows. In an exemplary, the operating lubrication pressure can be kept between 5 – 7 bar, operative lubrication concentration can be kept at 10±2%, and lubricant can be filled in mixing tank manually.
[00059] In an exemplary aspect, the proposed system can be operated based on a timer, and can be interfaced with PLC controls 600 of the press 700. Interfacing signals from the press 700 can be taken to the lubrication system. In an exemplary implementation, die lubrication in the proposed system 100 starts before start of the upsetting and the forming process, wherein the quantity of lubrication and duration of spray can be decided based on cycle duration and available time between finishing of operation on one wheel and charging of subsequent wheel.
[00060] In an exemplary aspect, the proposed automatic die lubrication system 100, for improvement in die life and better dimensional accuracy, can be interfaced with die movement, wherein, in the first operation, compressed air can be used to clean the dies, and then lubrication of top and bottom dies of upsetting and forming press can be carried out.
[00061] The proposed automatic system can be installed and commissioned, and this system working in both automatic as well as manual mode, can be interfaced with other press equipments. Sticker formation during forming process (between dies and work piece) can be reduced by around 50% after use of lubrication system. Rejections on account of forging at machining stage have also reduced by around 2%.
[00062] In an exemplary aspect, the proposed system 100 can be installed in a wheel forging plant, which can use close die forging process to manufacturer solid railway wheels. The proposed system can run successfully to reduce sticker formation between the work piece and dies by a large extent. The proposed system can further enable fire cracks occurring in dies to be reduced. Additionally, the proposed system can be installed in a grey field i.e. in working close die forging units also. The proposed system enables increase in die life, along with significantly reducing rejection on account of constrained metal flow.
[00063] In an aspect, the proposed system can be installed in any closed die forging unit. The proposed system can further be implemented at close die forging units having manual lubrication to improve die life and reduction in rejections.
[00064] As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other or in contact with each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously. Within the context of this document terms “coupled to” and “coupled with” are also used euphemistically to mean “communicatively coupled with” over a network, where two or more devices are able to exchange data with each other over the network, possibly via one or more intermediary device.
[00065] Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[00066] While some embodiments of the present disclosure have been illustrated and described, those are completely exemplary in nature. The disclosure is not limited to the embodiments as elaborated herein only and it would be apparent to those skilled in the art that numerous modifications besides those already described are possible without departing from the inventive concepts herein. All such modifications, changes, variations, substitutions, and equivalents are completely within the scope of the present disclosure. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.

ADVANTAGES OF THE INVENTION
[00067] The present invention improves die condition.
[00068] The present invention reduces sticker formation (between dies and work piece).
[00069] The present invention reduces rejections of wheel during machining stage by introduction of an automatic die lubrication system.

Claims:1. An automatic die lubrication system (100) comprising:
a tank assembly (200) configured to hold a lubricant;
a die lubricant spray unit (300) configured to spray said lubricant between one or more dies; and
a control unit (400) comprising a Programmable Logic Controller (PLC) for controlling one or more lubrication parameters during spraying of said lubricant between said one or more dies, said one or more parameters being selected from any or a combination of timing, flow, pressure, and concentration during multistage close die forging involving said one or more dies.
2. The system as claimed in claim 1, wherein said tank assembly (200) comprises a pneumatic pump (204) that is configured to supply said lubricant to spraying headers of each die of said one or more dies based on said one or more controlled lubrication parameters.
3. The system as claimed in claim 1, wherein said tank assembly (200) comprises a level indicator configured to alert lower level of lubricant in said tank assembly, based on which refilling of said lubricant is done in said tank assembly.
4. The system as claimed in claim 1, wherein said control unit (400) comprises a Human-Machine Interface (HMI) for centralized monitoring of said spraying.
5. The system as claimed in claim 1, wherein said tank assembly (200) further comprises any or a combination of a stiffener, and a stirrer 202,
6. The system as claimed in claim 1, wherein said die lubricant spray unit (300) further comprises any or a combination of a nozzle, a mixing block, a headers, and a hose.
7. The system as claimed in claim 1, wherein said system further comprises any or a combination of an Electric Resistance Welded (ERW) pipe and a control valve.
8. The system as claimed in claim 1, wherein said system is configured to work in any or a combination of both automatic and as well as manual modes.
9. The system as claimed in claim 1, wherein said system uses water soluble graphite (500) as the lubricant.
10. The system as claimed in claim 1, wherein working condition for said lubricant comprises keeping Block Temperature between the range of 12000C to 12500C, die temperature in the range of 3000-4000C, and operative lubrication concentration to be 10±2%.