FRICTION AND WEAR OF METAL-CUTTING AND METAL-FORMING TOOLS

1981 ◽  
pp. 195-226 ◽  
Keyword(s):  
Metal Forming ◽  
Friction And Wear ◽  
Metal Cutting ◽  
Forming Tools

Tribological Study of Vegetable Oil Based Lubricants - A Review

2019 ◽  
Vol 895 ◽  
pp. 212-217
Author(s):  
Deepak ◽  
T.P. Jeevan ◽  
S.R. Jayaram
Keyword(s):  
Vegetable Oils ◽  
Metal Forming ◽  
Friction And Wear ◽  
Metal Cutting ◽  
Tribological Behavior ◽  
Friction Reduction ◽  
Wear Performance ◽  
Environment Friendly ◽  
Petroleum Resources ◽  
Wear Reduction

Lubricants have a very crucial role in machinery industry for friction reduction and wear reduction between two relatively moving parts. The current study enlightens the works from various authors on evaluating the tribological behavior of environment friendly vegetable based oils as emerging biodegradable lubricants. The influences of the vegetable oils on friction and wear performance using different Tribometers were reported. The review focuses efforts on the development and commercialization of these vegetable based oils as industrial lubricants for manufacturing industries, mainly, metal forming and metal cutting. The review reveals that, many vegetable oils can be used as industrial lubricant, due to their exemplary attributes in terms of friction and wear reduction, which would help to decrease the universal demand of commercial lubricants which are based on petroleum resources to a great extent.

Amorphous Carbon Coatings for Locally Adjusted Tribological Properties in Sheet Bulk Metal Forming

2012 ◽  
Vol 504-506 ◽  
pp. 969-974 ◽  
Author(s):  
Harald Hetzner ◽  
Stephan Tremmel ◽  
Sandro Wartzack
Keyword(s):  
Amorphous Carbon ◽  
Tribological Properties ◽  
Metal Forming ◽  
Friction And Wear ◽  
Wear Properties ◽  
Carbon Coatings ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Friction And Wear Properties ◽  
Amorphous Carbon Coatings

In sheet bulk metal forming, locally adapted friction properties of the contact tool/workpiece are an appropriate means for the targeted enhancement of the material flow, enabling an improved form filling and lowered forming forces. However, the implementation of desirable friction conditions is not trivial. And further, friction is inseparably linked to wear and damage of the contacting surfaces. This calls for a methodological approach in order to consider tribology as a whole already in the early phases of process layout, so that tribological measures which allow fulfilling the requirements concerning local friction and wear properties of the tool surfaces, can already be selected during the conceptual design of the forming tools. Thin tribological coatings are an effective way of improving the friction and wear properties of functional surfaces. Metal-modified amorphous carbon coatings, which are still rather new to the field of metal forming, allow tackling friction and wear simultaneously. Unlike many other types of amorphous carbon, they have the mechanical toughness to be used in sheet bulk metal forming, and at the same time their friction properties can be varied over wide ranges by proper choice of the deposition parameters. Based on concrete research results, the mechanical, structural and special tribological properties of tungsten-modified hydrogenated amorphous carbon coatings (a-C:H:W) are presented and discussed against the background of the tribological requirements of a typical sheet bulk metal forming process.

Effect of transfer layers on friction and wear mechanisms in strip drawing tests of commercially coated forming tools

Wear ◽  
2021 ◽  
pp. 203733
Author(s):  
A.F. Tavares ◽  
A.P.O. Lopes ◽  
E.A. Mesquita ◽  
D.T. Almeida ◽  
J.H.C. Souza ◽  
...  
Keyword(s):  
Wear Mechanisms ◽  
Friction And Wear ◽  
Friction And Wear Mechanisms ◽  
Strip Drawing ◽  
Forming Tools

Tool Surface Topographies for Controlling Friction and Wear in Metal-Forming Processes

1998 ◽  
Vol 120 (3) ◽  
pp. 517-527 ◽  
Author(s):  
Simon Sheu ◽  
Louis G. Hector ◽  
Owen Richmond
Keyword(s):  
Surface Topography ◽  
Metal Forming ◽  
Friction And Wear ◽  
Workpiece Surface ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Single Scale ◽  
Surface Topographies ◽  
Tool Surface ◽  
Scale Surface

A conceptual framework is introduced for the design of tool surface topographies in bulk metal forming processes. The objective of the design is to control friction to desired levels while minimizing wear of the workpiece and tool surfaces and adhesive metal transfer between the workpiece and tool. Central to the design framework are the tool/workpiece interface properties of lubricant retention and interface permeability. Lubricant retention refers to the capacity of an interface to retain lubricant rather than freely channel it to the exterior of the tool/workpiece conjunction. Permeability refers to the capacity to distribute lubricant to all areas within the conjunction. These properties lead to the concept of two-scale surface topography consisting of a fine scale background of interconnected channels on which is superimposed an array of coarser-scale cavities. Control of friction and wear is achieved by designing the tool surface topographies at these two scales to address the unique tribological conditions of specific bulk metal forming processes. The coarser scale is designed to ensure adequate supply of lubricant within the conjunction. The finer scale is designed to ensure adequate delivery of lubricant to all parts of the conjunction where nascent workpiece surface is being formed. The design concepts are illustrated with results from laboratory experiments using the rolling process as an example, and comparing the performance of various roll surface topographies under similar processing conditions. A two-scale surface topography consisting of hemispherical cavities distributed across a background surface of finer scale, interconnected channels was shown to reduce friction compared to a single-scale ground finish, but not as much as a single-scale coarse topography consisting of densely-packed cavities produced by an electrical discharge treatment. On the other hand, the smoother cross-sections of the cavities, especially when elongated in the direction of greatest relative motion, produced significantly less wear than either of the single-scale tool surface treatments. It is concluded that two-scale engineering of tool surface topographies based upon the concepts of lubricant retention and interface permeability can provide a broad basis for achieving desired levels of interface friction while minimizing workpiece surface wear and adhesive material transfer in many metal-forming processes.

Design of Rotary Extrusion Process Using Simulation Techniques to Save Raw Material in Hollow Components

2015 ◽  
Vol 651-653 ◽  
pp. 254-259
Author(s):  
Ángela Mangas ◽  
Maite Santos ◽  
Jose Ignacio Zarazua ◽  
Iñaki Pérez
Keyword(s):  
Process Design ◽  
Metal Forming ◽  
Metal Cutting ◽  
Raw Material ◽  
Experimental Unit ◽  
Process Time ◽  
Deep Drilling ◽  
Flow Forming ◽  
Alternative Technology ◽  
Material Usage

The forging process plays an important role in the automotive industry thanks to the good mechanical properties of the forged parts. Nowadays, due to the European policy of increasing efficiency in raw material and energy usage, the metal forming sector is demanding new innovative technologies. In this context, rotary extrusion technology is a very promising metal forming alternative to the drilling techniques after forging processes.The presented work is focused on hollow shafts that are usually manufactured using a combination of forming and metal cutting techniques. Deep drilling is the most common technique to obtain internal holes in the automotive hollow parts, but it is an expensive process in terms of material usage. In this framework, rotary extrusion appears as an alternative technology that leads to the reduction of material usage and process time. The tubular shape is formed with the combination of two forming processes: flow forming and backward extrusion.This paper presents the development of a simulation methodology, the process design for a hollow part, the specifications of the experimental unit, and the manufactured prototypes in order to validate the simulation model. Also the incremental process is improved thanks to a sensitivity study of the rollers geometry. Rotary extrusion experiments are done using a modified flow forming machine and 20% material saving is achieved when obtaining the deep hole in comparison to the current deep drilling technology. The process design and numerical model tasks carried out try to provide the industry manufacturers an alternative technology to drilled parts considering the advantages of rotary extrusion parts.

scholarly journals Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

2018 ◽  
Vol 190 ◽  
pp. 02005 ◽  
Author(s):  
Markus Hirtler ◽  
Angelika Jedynak ◽  
Benjamin Sydow ◽  
Alexander Sviridov ◽  
Markus Bambach
Keyword(s):  
Additive Manufacturing ◽  
Metal Forming ◽  
Batch Size ◽  
Unit Costs ◽  
Batch Sizes ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
Forming Tools ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

Within the scope of consumer-oriented production, individuality and cost-effectiveness are two essential aspects, which can barely be met by traditional manufacturing technologies. Conventional metal forming techniques are suitable for large batch sizes. If variants or individualized components have to be formed, the unit costs rise due to the inevitable tooling costs. For such applications, additive manufacturing (AM) processes, which do not require tooling, are more suitable. Due to the low production rates and limited build space of AM machines, the manufacturing costs are highly dependent on part size and batch size. Hence, a combination of both manufacturing technologies i.e. conventional metal forming and additive manufacturing seems expedient for a number of applications. The current study develops a process chain combining forming and additive manufacturing. First, a semi-finished product is formed with forming tools of reduced complexity and then finished by additive manufacturing. This research investigates the addition of features using AlSi12 created by Wire Arc Additive Manufacturing (WAAM) on formed EN-AW 6082 preforms. By forming, the strength of the material was increased, while this effect was partly reduced by the heat input of the WAAM process.

Tribological Behaviour of PVD Coatings for Sheet Metal Forming Tools: Laboratory and Industrial Evaluation

2012 ◽  
Vol 504-506 ◽  
pp. 543-548 ◽  
Author(s):  
Francesco Sgarabotto ◽  
Andrea Ghiotti
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Vapour Deposition ◽  
New Technology ◽  
Research Work ◽  
Chemical Vapour ◽  
Tribological Behaviour ◽  
Wide Range ◽  
Forming Tools

In the last decades, Physical Vapour Deposition (PVD) and Chemical Vapour Deposition (CVD) processes have been significantly improved and optimized for the applications on dies for sheet metal forming processes. However, due to the different contact conditions at dies-blank interfaces, and the wide range of applied contact pressures, the selection of the correct coating may be still affected by trials-and-error approaches. Although many methods to evaluate the tribological performances of such coatings can be found in scientific literature, they often suffer of limitations in reproducing the interface conditions typical of industrial processes. The objective of the present research work is to investigate the tribological behaviour of two coatings deposited by PVD magnetron sputtering technique. Both investigations in laboratory and industrial conditions were performed: the former to evaluate their tribological characteristics, the latter to test the performances of coatings in production lines. The results, in terms of wear resistance, outline the comparison of the new technology with the performances of traditional dies.

SURFACE DAMAGE BEHAVIOR OF GALVANIZED STEEL SHEETS IN FORMING PROCESS UNDER TENSION-BENDING

2010 ◽  
Vol 24 (30) ◽  
pp. 5877-5884 ◽  
Author(s):  
Z. Q. YU ◽  
Y. K. HOU ◽  
S. H. LI ◽  
Z. Q. LIN ◽  
W. G. ZHANG
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Surface Damage ◽  
Galvanized Steel ◽  
Forming Process ◽  
Damage Resistance ◽  
Steel Sheets ◽  
Galvanized Steels ◽  
Part Surface ◽  
Forming Tools

The surface damage behaviors of different galvanized steel sheets were investigated under the condition of tension-bending. The U-channel forming tests were performed for HDGI (hot-dip galvanized) and HDGA (hot-dip galvannealed) steels. Experimental results indicate that HDGI steel shows better damage resistance than HDGA steel in sheet metal forming. Scratching is the main surface damage in the forming of HDGI steel while exfoliating and scratching of coating are two types of surface damage for HDGA steel. And tool hardness and surface topography have crucial effects on part surface damage in the forming of the two kinds of galvanized steels. Different surface treatments should be applied to the forming tools in the forming of HDGI and HDGA steels for better surface qualities of products.

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