Abstract
In the present study, the influence of a global adaption of the tribological conditions for a bulk forming process of microparts from sheet metal was analyzed numerically. Based on numerical determined requirements, suitable experimental methods were investigated to modify tribological conditions. For a global adjustment of the friction the influence of a workpiece-sided surface modification and lubrication was investigated. Thus, a dry and lubricated condition as well as flat and abrasively blasted workpiece surfaces, of high-purity oxygen-free copper (Cu-OFE) were analyzed. To evaluate the influence of these measures on friction conditions, the pin extrusion test as a laboratory friction test was used. The friction factors for the different tribological conditions were determined using numerical identification. In a numerical feasibility study, it was shown that the height of the micropin in the investigated process can be influenced by an adaption of the friction. The height of the micropin and thus the process can be improved by an increase of the friction. In this study, abrasive blasting of the workpiece surfaces and the use of non-lubricated copper sheets was identified as a suitable measure to increase the friction globally. By abrasive blasting the friction factor could be increased from m = 0.07 to m = 0.12 for a lubricated and from m = 0.16 to m = 0.50 for a dry condition.
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