Dry metal forming of high alloy steel using laser generated aluminum bronze tools

Hannes Freiße,Frank Vollertsen,Henry Köhler,Thomas Seefeld

doi:10.1051/matecconf/20152108011

Abstract

Regarding the optimization of forming technology in economic and environmental aspects, avoiding lubricants is an approach to realize the vision of a new green technology. The resulting direct contact between the tool and the sheet in non-lubricated deep drawing causes higher stress and depends mainly on the material combination. The tribological system in dry sliding has to be assessed by means on the one hand of the resulting friction coefficient and on the other hand of the wear of the tool and sheet material. The potential to generate tailored tribological systems for dry metal forming could be shown within the investigations by using different material combinations and by applying different laser cladding process parameters. Furthermore, the feasibility of additive manufacturing of a deep drawing tool was demonstrated. The tool was successfully applied to form circular cups in a dry metal forming process.

Highlights

Dry metal forming is a new approach to establish sustainable production technology in metal forming
The tribological system in dry sliding has to be assessed by means on the one hand of the resulting friction coefficient and on the other hand of the wear of the tool and sheet material
The potential to generate tailored tribological systems for dry metal forming could be shown within the investigations by using different material combinations and by applying different laser cladding process parameters

Summary

Introduction

Dry metal forming is a new approach to establish sustainable production technology in metal forming. Dry deep drawing of various sheet metals was investigated for example by controlled selective oxidation of cold work steel surfaces [3], by using ceramic tools [4] or by macro- and microscopically modified surfaces of a deep drawing tool [5]. Comprehensive tribological aspects in dry forming were presented by [6] Drawing tool surface can be modified using aluminum bronze coatings by laser cladding [7]. In this work an approach for dry metal forming is presented of using laser cladding as a production technology and aluminum bronze as a tool material to generate surfaces and to manufacture a deep drawing tool

Laser cladding and tribological testing

Additive manufacturing of a deep drawing tool

Dry metal forming of circular cups

Findings

Summary