Evaluation of Lubricants for Stamping of Al 5182-O Aluminum Sheet Using Cup Drawing Test

2015 ◽  
Vol 137 (5) ◽  
Author(s):  
Long Ju ◽  
Tingting Mao ◽  
Julio Malpica ◽  
Taylan Altan
Keyword(s):  
Surface Texturing ◽  
Tensile Tests ◽  
Friction Behavior ◽  
Aluminum Sheets ◽  
Drawing Test ◽  
The Coefficient Of Friction ◽  
Lubrication Condition ◽  
Flow Stress Data ◽  
Viscous Pressure ◽  
Cup Drawing

Lubricants are necessary to avoid adhesion, galling, and scratching in aluminum stamping processes. In this study, various lubricants, including dry lubes and wet lubes, were evaluated using cup drawing test (CDT) for stamping of Al 5182-O aluminum sheets. The effects of surface texturing, with electro-discharge texturing (EDT) and mill finish (MF), on the friction behavior were also investigated. Furthermore, the methodology to evaluate the performance of lubricants was established based on (a) maximum applicable blank holder force (BHF) and (b) draw-in length in flange or flange perimeter of formed cups. Finite element (FE) simulations were carried out to determine the coefficient of friction (CoF) at tool–workpiece interface during deep drawing under different lubrication conditions. Flow stress data of Al 5182-O material were obtained using viscous pressure bulge (VPB) and tensile tests. In this study, it was confirmed that, in forming Al 5182-O, dry film lubricants have better lubricity than wet lubricants. A better lubrication condition was found with EDT surface texture.

Effects of Rolling Direction and Lubricant on Friction in Sheet Metal Forming

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
Xiaojun Liu ◽  
Mathias Liewald ◽  
Dina Becker
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Rolling Direction ◽  
Alloy Sheet ◽  
Friction Behavior ◽  
Drawing Test ◽  
Strip Drawing ◽  
The Coefficient Of Friction ◽  
Surface Microstructures

Lubrication and friction at workpiece-tool interface play an important role in product quality control of sheet metal forming process. Surface microstructures of sheets have a great influence on the development of lubrication films. In order to investigate the effects of the rolling direction of aluminum alloy sheet and lubricant on the friction behavior in sheet metal forming, strip drawing test was used. The sample used was electric discharge texturing (EDT) surface. Lubricants, both with and without additives, were used. The strip drawing tests were performed at angles between the sliding and rolling directions of 0–90 deg. Variations in the sheet surface topography were analyzed by comparing the sheet surface microstructures and its 3D surface parameters before and after the strip drawing test. Results of the strip drawing tests indicate that the kind and amount of lubricant have great influences on friction at the interface, and the lubricant with additives benefits improving the friction behavior between the sheet and the tool. The EDT surface of the aluminum alloy sheet has an anisotropic frictional property during deep drawing process due to different angles between the sliding and rolling directions. When the sliding direction is parallel to the rolling direction, the coefficient of friction has the highest value. When the angle between the sliding and rolling directions increases, the coefficient of friction decreases. The surface microstructure of the sheets after the strip drawing test at different angles between the sliding and rolling directions has been modified, and its 3D surface parameters decrease significantly to a different degree.

Mechanical and tribological study of short glass fiber-reinforced PA 66

2019 ◽  
Vol 27 (9) ◽  
pp. 587-596 ◽  
Author(s):  
R Autay ◽  
S Missaoui ◽  
J Mars ◽  
F Dammak
Keyword(s):  
Glass Fiber ◽  
Coefficient Of Friction ◽  
Weight Fraction ◽  
Tensile Tests ◽  
Fiber Direction ◽  
Scanning Electron Micrographs ◽  
Ambient Conditions ◽  
Friction Behavior ◽  
The Coefficient Of Friction ◽  
Short Glass

Tensile, flexural, wear, and friction behaviors of polyamide 6.6 (PA 66) reinforced by different weight fractions of short glass- iber were investigated. Three-point bending flexural tests in addition to monotonic tensile tests were carried out to determine the mechanical behavior. Reciprocating friction tests were carried out without lubrication under ambient conditions. A ball-on-flat contact configuration was adopted for all tests. Reciprocating wear tests were carried out against a silicon carbide abrasive paper. Results show that the reinforcement influenced mechanical and tribological behaviors and that the orientation of glass fiber has an effect on the friction behavior. Increasing the weight fraction of glass fiber increases the ultimate strength, the flexural strength, and the elastic modulus but decreases the elongation at break. Increasing the weight fraction of glass fiber decreases the coefficient of friction and increases the wear rate. For high weight fractions, when sliding parallel to the glass fiber direction, the coefficient of friction is smaller than which is measured in the perpendicular direction. Abrasive wear mechanism of wear was illustrated via scanning electron micrographs.

Friction reduction in EHL contacts by surface microtexturing – tribological performance, manufacturing and tailored design

2019 ◽  
Vol 71 (8) ◽  
pp. 986-990 ◽  
Author(s):  
Stephan Tremmel ◽  
Max Marian ◽  
Michael Zahner ◽  
Sandro Wartzack ◽  
Marion Merklein
Keyword(s):  
Product Life Cycle ◽  
Structural Parameters ◽  
Surface Texturing ◽  
Friction Reduction ◽  
Forming Process ◽  
Friction Behavior ◽  
Holistic View ◽  
Content Type ◽  
Efficient Manufacturing ◽  
Tailored Design

Purpose This paper aims to derive tailor-made microtextures for elastohydrodynamically lubricated (EHL) contacts under consideration of manufacturing possibilities. Design/methodology/approach Component tests were used for the evaluation of the influence of surface texturing on the friction behavior in the cam/tappet contact. Furthermore, the manufacturing possibilities and limitations of a combined μEDM and micro-coining process and the feasibility of integration into a forming process were studied. Finally, a methodology based on transient EHL simulations and a meta-model of optimal prognosis was exemplarily used for microtexture optimization. Findings It was found that surface texturing in EHL contacts with high amount of sliding is promising. Moreover, the combination of μEDM and micro coining and the integration into established production processes allow the manufacturing of microtextures with desirable structural parameters and sufficient accuracy. Originality/value This paper gives a holistic view on surface microtexturing over several phases of the product life cycle, from the design, over efficient manufacturing to application-related testing.

Investigation of the friction behavior of plasma spray Mo/NiCrBSi coated brake discs

2021 ◽  
Vol 63 (3) ◽  
pp. 259-265
Author(s):  
Halil Kılıç ◽  
Cenk Mısırlı ◽  
İbrahim Mutlu
Keyword(s):  
Coefficient Of Friction ◽  
Plasma Spray ◽  
Wear Behavior ◽  
Atmospheric Plasma ◽  
Brake Disc ◽  
Friction Behavior ◽  
Braking Performance ◽  
Spray Process ◽  
The Coefficient Of Friction ◽  
Nicrbsi Coating

Abstract This paper presents the findings of comparative research conducted to find out the braking performance of a Mo/NiCrBSi coated automobile brake disc. The friction and wear behavior of the Mo/NiCrBSi coating (CD) used for the disc material was evaluated using a laboratory scale disc-pad dynamometer and compared with a reference disc (RD). The coating was deposited by means of the atmospheric plasma spray process on a grey cast iron substrate. Braking tests were performed according to the SAE-J2430 test standard. Disc microstructures were characterized by SEM and XRD. It was found that the bonding strength was good with an infinite rating between the accumulated coating layer and the substrate. The results show that the coated brake disc has a comparable coefficient of friction and that the amount of wear is lower than that of the reference disc. The addition of ductile phases to the disc coating was beneficial in reducing the coefficient of friction to an acceptable degree and also effectively improving wear resistance.

scholarly journals Possibilities of Dry and Lubricated Friction Modification Enabled by Different Ultrashort Laser-Based Surface Structuring Methods

Lubricants ◽  
2019 ◽  
Vol 7 (5) ◽  
pp. 43 ◽  
Author(s):  
Stefan Rung ◽  
Kevin Bokan ◽  
Frederick Kleinwort ◽  
Simon Schwarz ◽  
Peter Simon ◽  
...  
Keyword(s):  
Laser Beam ◽  
Surface Engineering ◽  
Surface Texturing ◽  
Friction Reduction ◽  
Surface Structures ◽  
Laser Surface Texturing ◽  
Periodic Surface ◽  
The Coefficient Of Friction ◽  
Disc Configuration ◽  
Micro Structures

In this contribution we report on the possibilities of dry and lubricated friction modification introduced by different laser surface texturing methods. We compare the potential of Laser-Induced Periodic Surface Structures and Laser Beam Interference Ablation on 100Cr6 steel in a linear reciprocating ball-on-disc configuration using 100Cr6 steel and tungsten carbide balls with load forces between 50 mN and 1000 mN. For dry friction, we find a possibility to reduce the coefficient of friction and we observe a pronounced direction dependency for surfaces fabricated by Laser Beam Interference Ablation. Furthermore, Laser-Induced Periodic Surface Structures result in a load-dependent friction reduction for lubricated linear reciprocating movements. This work helps to identify the modification behaviour of laser generated micro structures with feature sizes of approximately 1 µm and reveals new possibilities for surface engineering.

Friction Behavior in the Cup Ironing Process of Aluminum Sheets

1992 ◽  
Vol 114 (2) ◽  
pp. 175-180 ◽  
Author(s):  
N. Kawai ◽  
K. Dohda ◽  
M. Saito ◽  
N. Hayashi ◽  
Z. Wang
Keyword(s):  
Friction Coefficient ◽  
Friction Behavior ◽  
Surface Flattening ◽  
Aluminum Sheets ◽  
Experimental Apparatus ◽  
Die Surface ◽  
Lubricating Mechanism

The object of this paper is to clarity the surface flattening mechanism in the cup ironing process based on the lubricating mechanism. A new experimental apparatus for the ironing process was made and experiments on ironing were carried out with aluminum cups using various lubricants and reductions in thickness. The experiments revealed that on the die surface the friction coefficient becomes minimum under the appropriate conditions of viscosity of lubricant and reduction in thickness. It was also confirmed that the cup surface is best flattened under conditions where the minimum friction coefficient appears.

Microstructure and Tensile Properties of Ultrafine Grained Pure Al Sheets Produced by Accumulative Roll Bonding

2011 ◽  
Vol 284-286 ◽  
pp. 993-996
Author(s):  
Kun Xia Wei ◽  
Wei Wei ◽  
Qing Bo Du ◽  
Jing Hu
Keyword(s):  
Tensile Tests ◽  
Rolling Plane ◽  
Recrystallization Process ◽  
Bonding Quality ◽  
Softening Behavior ◽  
Aluminum Sheets ◽  
Transmission Electron ◽  
Ultrafine Grained ◽  
Strain Hardening Behavior ◽  
Adjacent Cycles

Usually the heat treatment in the cyclic ARB passes is indispensable to reduce work-hardening effects and improve interface bonding quality. The possibility of accelerating grain refinement of aluminum sheets with a dimension of 300 mm×50 mm×1 mm is investigated during the ARB process at room temperature, in which the samples are rotated by 180 degree around normal plane axis perpendicular to the rolling plane between the adjacent cycles. By means of optical microscopy and transmission electron microscopy, it shows that the bonding interfaces can not obviously observed after five cycles, and grains are refined to be ~0.5 μm. Tensile tests show the ARB samples exhibit strain hardening behavior after yielding without a sudden fracture even up to seven cycles of ARB. The softening behavior and enhanced ductility was explained by dynamic recovery, the recrystallization process and even abnormal large grains.

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