Abstract
Like in many other production technologies, a broad process window for metal forming is desired. The goal is always a stable process chain. One of the key aspects for metal forming are stable tribological conditions. Instabilities can be caused by, amongst others, different material batches, change in temperature during the production process, different lubricant amounts and different stroke rates. At the beginning of a production run, the tribological stability suffers from transient temperature effects caused by plastic and frictional work and a viscosity drop of the lubricant. To control the tribology, different strategies are suitable: changing the oil type, the oil amount, the blank holder force or the stroke rate. Within the EU-project ASPECT, control strategies on blank holder forces are developed as well as lubricants with improved stability on their behaviour as a function of temperature. This paper will focus on the latter. In preliminary ball on plate test the friction and wear of lubricant formulations were investigated and compared to a Reference lubricant. Followed by strip drawing and forming tests. Finally, the concept is proven in trials on a demonstrator line, which is close to serial production.
Highlights
Factors, which have an influence on friction Within the project ASPECT (“Advanced Simulation and Control of tribology in metal forming Processes for the NorthWest European Consumer goods and transport sectors”), co-funded by the INTERREG North West Europe Program, the partner consortium tried to solve these demands by using simulations, process control strategies, adapted lubricants and we investigated the hypothesis with the demonstrator tools
With every stroke at the deep drawing process, fresh areas of the sheet metal were exposed to the tool surface [2]
In contrast to the deep drawing process, the ball on plate test has a repetitive contact with the same area of the friction partner
Summary
Rolling, bending, cutting, forging and deep drawing are common processes for sheet metal working. For the most of these processes, lubrication is needed to protect the tool from wear and to achieve smooth operation conditions. Forming lubricants have to meet a broad range of demands beside the effective lubrication. These are the application, the material compatibility, environmental requirements, work safety, the local registration of the additives and the final degreasing step after the processing. The most important are the stroke rate (velocity), pressure, material and surface properties, strain and temperature [4]. Higher Productivity In Forming High-alloyed Steel By Temperature Insensitive Friction B
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