Abstract
Cold metal forming is a fast and economical way of producing a wide range of precise components. Its profitability mainly depends on part quality, process stability, and service intervals of tools. As these factors are all determined by tool wear, detailed process knowledge is indispensable to maximize profitability by minimizing wear. One of the most crucial factors in this context is temperature. During every forming process, a temperature rise occurs between tool and workpiece due to frictional heating and a large part of plastic work dissipating into heat. This phenomenon affects the whole forming process but especially tool wear. Currently, there is little solid information about temperatures occurring during forming operations. Therefore, the temperature was measured based on varying process parameters, sheet materials, and thicknesses in several embossing and blanking examinations. The use of a tool–workpiece thermocouple enabled accurate and instantaneous measurement during the process. The results presented show the strong influence of process and material parameters on temperatures in the forming zone.
Highlights
Cold metal forming and blanking are among the most frequently used mass production processes for sheet metal
As the maximum temperatures occur with the end of clean-cut formation and the maximum embossing depth, a complete sheet metal separation is done
This paper presents an instantaneous thermoelectricitybased method for measuring temperatures occurring in the forming zone during embossing
Summary
Cold metal forming and blanking are among the most frequently used mass production processes for sheet metal. During every forming operation, a temperature rise occurs in the workpiece’s forming zone. This effect has three causes: first, up to 95% of the plastic work dissipates into heat [1]. During forming operations with high surface pressures and deformation degrees, such as embossing or blanking, temperatures of several hundred degrees can occur, as shown below. The temperature rise strongly influences the process. Temperature is a decisive factor in the choice of tool coatings and lubricants [5]. Precise knowledge of the height and profile of the temperature that occurs is indispensable with respect to process parameters
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