Abstract
Aiming to decrease friction coefficient () during the forming of magnesium alloy sheets, nine (9) tools with different hole geometries in their surface (flat, elliptical, and circular) were manufactured from steel Boehler W400 VMR (as known as DIN 1.2343). Tribological investigations were accomplished on a strip drawing machine at 288 °C without lubricants. When compared with a standard tool (surface flat), on average, tools with circular geometries in their surface showed the smallest friction coefficient, while tools with elliptical geometries shown higher. The friction coefficient also was confronted with the ratio between area occupied by holes in the surface of the tool and the total tool surface (i.e., factor f (%)), hole diameter (Ø), and the distance between circle centers (d(c,c)). Principal Component Analysis (PCA) complemented the experimental approach. In summary, both approaches (experimental and theoretical) indicated that the manufactured tool with circular geometries on its surface presented lower friction coefficient values on the forming processes of the magnesium AZ31 sheets.
Highlights
Energy efficiency increasing by means of less fuel consumption is directly related to metal forming processes
The tool with circular geometries on its surface showed a reduction of 8.9% on the friction coefficient when compared with a standard tool
The same was not observed for tools with ellipsoidal geometries in its surface, in which the friction coefficient increased in comparison with the tool 1
Summary
Energy efficiency increasing by means of less fuel consumption is directly related to metal forming processes. Researches on these technologies are essential for the automotive industry to accomplish the vehicle weight reduction. The use of lubricants and the relatively high values of the friction coefficient are the biggest problems to forming sheets from magnesium alloys [1,2,3]. After the forming process, these lubricants should be removed from magnesium alloys parts, as soon as possible, in order to prevent corrosion and problems in their cleaning [7,8,9]. If the lubricant cannot be removed from the component surface, the subsequent layer applied to prevent corrosion will present poor adhesion
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