Common Mistakes in Punching and Press Operations

In punching and press forming operations, rising defect rates are often blamed on tooling or equipment issues. However, in many cases, the root cause is incorrect lubricant selection.

Punching oil is not just a consumable—it directly affects process stability, product quality, tool life, and overall manufacturing cost. This article highlights common lubricant selection mistakes that lead to higher defect rates and explains how to avoid them.

1. Using Lubricants with Excessively High Viscosity

Burr Formation and Dimensional Inconsistency

Problem Scenario

When high-viscosity lubricants are used in high-speed punching operations, the oil cannot evacuate quickly from the tool–workpiece interface. This results in uneven lubrication films and unstable cutting conditions.

Resulting Defects

• Increased burr formation
• Tearing or rough sheared edges
• Poor dimensional accuracy

Best Practice

• Use low-viscosity, high-flow punching oils for high-speed operations
• Match lubricant viscosity to punching speed and die clearance

2. Ignoring Material-Specific Lubrication Requirements

Sticking and Galling Issues

Problem Scenario

Applying general-purpose steel lubricants to aluminum punching processes.

Resulting Defects

• Material sticking and galling
• Surface scratches and material transfer
• Frequent line stoppages

Best Practice

• Select non-ferrous–compatible punching oils
• Ensure additive packages are optimized for aluminum alloys

3. Insufficient Cooling Performance

Discoloration and Thermal Damage

Problem Scenario

Using lubricants with poor heat dissipation in high-speed or continuous punching.

Resulting Defects

• Material discoloration
• Burn marks on punched edges
• Oxidation-related downstream defects

Best Practice

• Choose punching oils that balance lubrication and cooling performance
• Prioritize thermal stability for high-throughput operations

4. Overlooking Cleanability and Residue Control

Downstream Process Failures

Problem Scenario

Using high-residue oils when washing, welding, or coating processes follow punching.

Resulting Defects

• Incomplete cleaning
• Welding defects
• Coating adhesion failures

Best Practice

• Use low-residue, high-cleanability punching oils
• Evaluate lubricant compatibility with downstream processes

5. Focusing Only on Low Cost

Long-Term Quality and Cost Problems

Problem Scenario

Selecting lubricants solely based on price.

Long-Term Impact

• Increased defect rates
• Accelerated tool wear
• Higher maintenance costs
• Increased total manufacturing cost

Best Practice

• Evaluate lubricants based on Total Cost of Ownership (TCO)
• Consider defect reduction, tool life, and uptime—not just oil price

Conclusion: Lubricant Selection Is a Quality Strategy

Incorrect lubricant selection does more than increase scrap—it undermines process stability, shortens tool life, and raises overall production costs.

Key Checklist for Proper Punching Oil Selection

• Compatibility with material (aluminum, steel, stainless steel)
• Punching speed and thermal load
• Appropriate viscosity and flow characteristics
• Balanced lubrication and cooling performance
• Compatibility with cleaning, welding, and coating processes

The right punching oil reduces defects, stabilizes production, and delivers measurable cost savings.

Dyna Co., Ltd.
Industrial Lubricant Solution
E-Mail : dyna@dynachem.co.kr
Web : dyna.co.kr/en/