{"id":8565,"date":"2025-09-22T11:01:10","date_gmt":"2025-09-22T02:01:10","guid":{"rendered":"https:\/\/www.dry-fog.com\/en\/?post_type=cases&#038;p=8565"},"modified":"2025-09-22T12:03:12","modified_gmt":"2025-09-22T03:03:12","slug":"nozzle-metal-001","status":"publish","type":"cases","link":"https:\/\/www.dry-fog.com\/en\/projects-technology\/cases\/nozzle-metal-001\/","title":{"rendered":"Lubricant Spraying in Press Forming | Ultra-Low Pulse Control for Reduced Consumption"},"content":{"rendered":"<section>\n<p><!-- Key Reasons for Implementation \u2605\u7b87\u6761\u66f8\u304d --><\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.5rem\">Key Reasons for Implementation<\/h3>\n<\/div>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1rem;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem\">\n<li>Selected a lubrication nozzle with a pilot-air spray on\/off function, preventing excessive application caused by dripping.<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem\">\n<li>Achieved an ultra-low flow rate of just 2 cc per second per nozzle.<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem\">\n<li>Proposed a system with multiple nozzles mounted on a header, offering the function to selectively activate nozzles according to blank (workpiece) size.\n<\/li>\n<\/div>\n<\/ul>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"float: left;padding-top:1.5rem;padding-left: 2rem\">\n<img decoding=\"async\" loading=\"lazy\" src=\"https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/call-1.jpg\" alt=\"\" width=\"330\" height=\"296\" class=\"alignleft size-medium wp-image-5969\" \/>\n<\/div>\n<div style=\"float: right;margin-top: 4rem;margin-right: 3%\">\n<ul style=\"list-style-type: none;margin-left:0rem;font-size: 1.2rem;font-weight: bold;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Not sure which product is right for you?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Curious about the total cost?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Wondering where to start?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;font-size: 0.8rem;font-weight: bold;padding-left: 30px\">\n<li>We\u2019re here to help \u2013 reach out with any questions.<\/li>\n<\/div>\n<\/ul>\n<div style=\"text-align:center;margin-top:2rem;margin-bottom: 2rem\">\n<a style=\"margin-bottom:1rem;margin-left:2rem;justify-content: center;align-items: center;padding: 0.5rem 4rem;color: #fff;font-weight: 500;font-size:1.2rem;width:auto;background: #0C9B6F;border-radius: 30px\" href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" target=\"_blank\" rel=\"noopener\">Contact Us<\/a>\n<\/div>\n<\/div>\n<div style=\"clear:both\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:0rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<p><!-- Purpose of Lubrication in Press Forming\u3000\u2605p\uff5e\/p\u3067\u6bb5\u843d\u533a\u5207\u308a --><\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.5rem\">Purpose of Lubrication in Press Forming<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">Press forming is a manufacturing process in which sheet metal (or other workpieces\/blanks) is pressed against a die to form the desired shape. It is widely used across industries such as automotive and electrical component production. <\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2025\/09\/nozzle-metal-001-image_01.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">The primary purposes of applying lubricating oil to metal blanks (workpieces) in press forming are as follows:<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">1. Reducing Friction<br \/>\nLubricating oil forms an oil film between the die and the workpiece, reducing friction. This allows smoother metal forming and contributes to improved processing accuracy.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">2. Protecting Dies and Related Components<br \/>\nProper lubrication protects dies and associated components from wear and overheating, contributing to extended die life.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">3. Assisting in Forming Difficult-to-Process Areas<br \/>\nIn processes involving large deformation, such as deep drawing or complex shaping, lubricating oil reduces forming loads and helps prevent cracking or wrinkling of the workpiece.<\/p>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<p><!-- Challenges Faced by the Customer\u3000\u2605p\uff5e\/p\u3067\u6bb5\u843d\u533a\u5207\u308a --><\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.5rem\">Challenges Faced by the Customer<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">A press machine manufacturer developing a new model consulted us on the selection of lubrication nozzles to be used in their machine.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">\nThey wanted to avoid the roller method that applies lubricant by direct contact with the workpiece, as it tends to wear quickly, and instead aimed to adopt a non-contact spray nozzle system.<br \/>\nHowever, the two nozzle types they were considering each had their own advantages and disadvantages, leaving them uncertain about the final choice.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">First, <span style=\"font-weight:bold;font-size: 1rem\">pneumatic (twin-fluid) nozzles<\/span>, also known as air atomizing spray nozzles, generate a fine mist by mixing compressed air with the liquid, thereby reducing lubricant consumption. However, because of the air mixing, the mist tends to disperse easily and contaminate the surrounding area.<br \/>\nIn addition, the use of compressed air entails ongoing operating costs.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">On the other hand, <span style=\"font-weight:bold;font-size: 1rem\">hydraulic (single-fluid) nozzles<\/span> that spray by pressurizing the liquid are prone to dripping, resulting in excessive application and increased overall consumption of the lubricant.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">The size of the blanks (workpieces) to be press-formed varies by production lot, ranging widely from 95 mm to 800 mm. Larger workpieces require multiple nozzles installed across the line width to ensure full coverage. Conversely, for smaller workpieces, the customer wanted to <span style=\"font-weight:bold;font-size: 1rem\">minimize waste by reducing the number of active nozzles and applying lubricant only to the necessary area<\/span>.<\/p>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<p><!-- Solutions Proposed by IKEUCHI\u3000\u2605p\uff5e\/p\u3067\u6bb5\u843d\u533a\u5207\u308a \u2605\u753b\u50cfURL\u3092\u201d\u3053\u3053\u306bURL\"\u306e\u4f4d\u7f6e\u306b\u5165\u308c\u308b\u3002\u753b\u50cf\u30b5\u30a4\u30ba\u306f\u5143\u548c\u6587HTML\u53c2\u8003\u3000--><\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.5rem\">Solutions Proposed by IKEUCHI<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">We selected <span style=\"font-weight:bold;font-size: 1rem\">hydraulic spray nozzles that minimize mist dispersion<\/span> and do not require compressed air for spraying, thereby <span style=\"font-weight:bold;font-size: 1rem\">reducing operating costs<\/span>.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">Then, from among flat spray pattern nozzles with a wide spray width, we proposed the <span style=\"font-weight:bold;font-size: 1rem\">anti-drip SO-V Series<\/span>, which enables <span style=\"font-weight:bold;font-size: 1rem\">responsive spray on\/off control via pilot air<\/span>. This feature <span style=\"font-weight:bold;font-size: 1rem\">prevented dripping and excessive application<\/span>, ensuring precise lubrication.<br \/>\nFurthermore, by choosing the model with the lowest flow rate in the series, we reduced the spray volume to <span style=\"font-weight:bold;font-size: 1rem\">just 2 cc\/sec per nozzle<\/span>.<\/p>\n<p><a href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-hyd-so-v\/\" style=\"color: #00a273\" target=\"_blank\" rel=\"noopener\"><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2025\/09\/nozzle-metal-001-image_02.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/a><br \/>\nSO-V Series<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">By mounting five SO-V nozzles on a header, the system can cover blanks (workpieces) up to 800 mm in width. For smaller workpieces, deactivating unneeded nozzles allows <span style=\"font-weight:bold;font-size: 1rem\">lubrication only over the required area, helping to reduce fluid consumption<\/span>.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2025\/09\/nozzle-metal-001-image_03.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><br \/>\nNote: The wavy lines indicate omitted sections. In practice, five nozzles are installed on the header.<\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto;text-align:center;margin-top:3rem\">\n<iframe loading=\"lazy\" width=\"100%\" height=\"422\" src=\"https:\/\/www.youtube.com\/embed\/AUZlteRQf_k?cc_lang_pref=en&amp;cc_load_policy=1\" title=\"YouTube video player\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\"><\/iframe><\/div>\n<p>Spray on\/off control in operation<\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<p><!-- Benefits Achieved\u3000\u2605\u672c\u6587\u6bb5\u843d\u3068\u7b87\u6761\u66f8\u304d\u3000--><\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/10px-45px.svg) no-repeat 0 0;background-size:auto 30px;padding-left: 20px\">\n<h3 style=\"font-size: 1.5rem\">Benefits Achieved<\/h3>\n<\/div>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">All of the customer\u2019s requirements were successfully met, leading to installation in the next-generation press machine. Moreover, we have continued to receive repeat orders when improving current models.<br \/>\nIKEUCHI\u2019s nozzles continue to contribute to lubricant savings and efficient application today.\n<\/p>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto;text-align:center;margin-top:3rem\"><iframe loading=\"lazy\" width=\"100%\" height=\"422\" src=\"https:\/\/www.youtube.com\/embed\/DRZc4QK6n5A\" title=\"YouTube video player\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\"><\/iframe><\/div>\n<p>Pulse spraying with the SO-VV, the sister model of the SO-V Series\n<\/p><\/div>\n<\/section>\n","protected":false},"featured_media":0,"template":"","cat_cases":[87],"tag_cases":[542,383],"acf":[],"_links":{"self":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases\/8565"}],"collection":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases"}],"about":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/types\/cases"}],"wp:attachment":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/media?parent=8565"}],"wp:term":[{"taxonomy":"cat_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cat_cases?post=8565"},{"taxonomy":"tag_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/tag_cases?post=8565"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}