Off-Line Testing of Tribo-Systems for Sheet Metal Forming Production

Abstract:

Off-line testing of new tribo-systems for sheet metal forming production is an important issue, when new, environmentally benign lubricants are to be introduced. To obtain useful results it is, however, vital to ensure similar conditions as in the production process regarding the main tribo-parameters, which are tool/workpiece normal pressure, sliding length, sliding speed and interface contact temperature. The paper describes a generic methodology for such tests exemplified on an industrial, multistage deep drawing example, where deep drawing is followed by two successive re-drawing operations leading to very high tool/workpiece interface pressure and temperature in the second re-draw. Under such conditions only the best lubricant systems work satisfactory, and the paper shows how the performance of different tribo-systems in production may be predicted by off-line testing combined with numerical modelling in order to ensure proper test conditions.

• Periodical: Advanced Materials Research (Volumes 966-967)
• Pages: 3-20
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.966-967.3
• Online since: June 2014
• Authors: Nils Bay*, Ermanno Ceron
• Keywords: Modelling of Tribo-Parameters, Off-Line Testing of Tribo-Systems, Sheet Metal Forming

References

[1] Bay, N., Azushima, A., Groche, P., Ishibashi, I., Merklein, M., Morishita, H., Nakamura, T., Schmid, S., Yoshida, M.: Environmentally Benign Tribo-systems for Metal Forming, Keynote paper, CIRP Annals – Manufacturing Technology, 2010, 59 (2), pp.760-780.

DOI: 10.1016/j.cirp.2010.05.007

[2] European Parliament, Council, 2006, REACH, EC Regulation No 1907/2006 of the European Parliament and of the Council.

[3] Ministry of Environment, Government of Japan, http: /www. env. go. jp/en/laws/policy/basic/index. html , Jan. (2013).

[4] CDC Center for Disease Control and Prevention, USA, Criteria for a Recommended Standard: Occupational Exposure to Metalworking Fluids, http: /www. cdc. gov/niosh/docs/98-102.

[5] Nielsen, P.S., Friis, K.S., Bay, N.: Testing and modelling of new tribo-systems for sheet metal forming of stainless steel in laboratory and production. Proc. IMechE - Journal of Engineering Tribology. Special issue on Tribology Research in Scandinavia. Vol. 225, 2011, 1036-1047.

DOI: 10.1177/1350650111415331

[6] Madsen, E., Grundfos: Personal communication (2010).

[7] Ceron, E., Bay, N.: Testing and prediction of limits of lubrication in sheet metal forming. Proceedings of International Deep Drawing Research Group Conference, Mumbai 2012, pp.251-257.

[8] Bay, N., Olsson, D.D., Andreasen, J.L.: Lubricant Test Methods for Sheet Metal Forming. Tribology Int. 41/9 (2008) 844-853.

DOI: 10.1016/j.triboint.2007.11.017

[9] Ceron, E., Bay, N.: Determination of friction in sheet metal forming by means of simulative tribo-tests, Key Engineering Materials, 549 (2013) 415-422.

DOI: 10.4028/www.scientific.net/kem.549.415

[10] Ceron, E.: New tribo-systems for sheet metal forming of advanced high strength steels and stainless steels. PhD thesis, DTU-MEK, Technical University of Denmark, July (2013).

[11] Ceron, E., Bay, N.: A methodology for off-line evaluation of new environmentally friendly tribo-systems for sheet metal forming, CIRP Annals - Manufacturing Technology, 2013, 62 (1), pp.231-234.

DOI: 10.1016/j.cirp.2013.03.062

[12] Ceron, E., Martins, P.A.F., Bay, N.: Thermal analysis of Bending Under Tension test. Proceed. 11th Int. Conf. on Technology of Plasticity, ICTP 2014, 19-24 October 2014, Nagoya Congress Center, Nagoya, Japan.

[13] Ceron, E., Olsson, M., Bay, N.: Lubricant film breakdown and material pick-up in sheet forming of advanced high strength steels and stainless steels when using environmental friendly lubricants. Proceed. Int. Conf. on Tribology in Manufacturing Processes & Joining by Plastic Deformation, ICTMP2014, 22. -24. June, 2014, Darmstadt.

DOI: 10.4028/www.scientific.net/amr.966-967.219