Abstract
Processing high strength sheet metal materials causes high tribological loads to the surface of forming tools. To increase the wear resistance and therewith the service time of tools, surface coatings containing hard materials are applied by thermal spraying. In the initial “as sprayed” state, the coatings show a rough surface and porous structure, which is not suitable for sheet forming tools. This article describes the finishing of the coatings by subsequent roller burnishing. By the rolling process surface asperities of the coating are flattened and the contact area between the finished surface and the sheet is increased. Furthermore, residual compressive stresses in the surface zone are generated by the rolling process. The tribological properties of the coated and finished surfaces are analyzed in strip drawing tests with uncoated DP600 sheets varying the contact pressure and drawing velocity. It is shown that the process parameters of the roller burnishing process have a strong influence on the surface topology of the friction elements and their tribological properties. The coated and finished friction elements are compared to conventional grinded steel friction elements, made of C60.
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