Alternative Lubricants: Study on Plant-Based Lubricants in Metal Forming Process

2016 ◽  
Vol 819 ◽  
pp. 469-473
Author(s):  
M.A. Nurul ◽  
Samion Syahrullail
Keyword(s):  
Pure Aluminum ◽  
Cold Work ◽  
Viscosity Index ◽  
Experimental Result ◽  
Forming Process ◽  
Lower Viscosity ◽  
Experimental Apparatus ◽  
Billet Material ◽  
Metal Forming Process ◽  
Taper Die

In this paper, the effect of metal-to-metal contact from the application of plant-based lubricants, RBD palm olein and jatropa were investigated by cold work forward plane strain extrusion experiments. A pair of taper die and a symmetrical workpiece (billet) was placed inside extrusion rig which acted as main experimental apparatus. The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the lower viscosity index, will lead to lower friction effect to the deformed area, as well as product area.

Evaluation of Paraffinic Mineral Oil as Lubricant in Cold Work Extrusion Process

2014 ◽  
Vol 554 ◽  
pp. 327-331 ◽  
Author(s):  
Samion Syahrullail ◽  
Mohd Ahyan Nurul Aini
Keyword(s):  
Plane Strain ◽  
Pure Aluminum ◽  
Cold Work ◽  
Extrusion Process ◽  
Mineral Oil ◽  
Experimental Result ◽  
Friction Effect ◽  
Billet Material ◽  
Deformation Area ◽  
Taper Die

In this paper, the effect of frictional constraint from the application of three different viscosity of additive free paraffinic mineral oil as lubricant were investigated by cold work forward plane strain extrusion experiments. The experiment used a cold work plane strain extrusion apparatus consist of a pair of taper die and a symmetrical workpiece (billet). The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the higher viscosity, will lead to lower friction effect to the deformed area, as well as product area.

DETERMINING ALTERNATIVES FOR METAL FORMING LUBRICANTS: A STUDY USING PLANE STRAIN COLD EXTRUSION PROCESS OF JIS-A1100 PURE ALUMINUM BILLET

2015 ◽  
Vol 74 (10) ◽  
Author(s):  
M. A. Nurul ◽  
S. Syahrullail ◽  
M. N. Musa
Keyword(s):  
Product Quality ◽  
Plane Strain ◽  
Renewable Resources ◽  
Metal Forming ◽  
Pure Aluminum ◽  
Cold Work ◽  
Cold Extrusion ◽  
Film Material ◽  
Ability To Act ◽  
Taper Die

Lubrication is very important in metal forming processes to control wear and friction at the interface between interacting surfaces. Non-renewable resources, such as plain mineral oils are widely used due to its ability to act as a supplier to wearing contacts; it may function as a film material or even sustain chemical transformations to become a film material. Since non-renewable resources can only last for more than a decade, renewable resources have been studied in order to find alternative lubricants that can present similar results in terms of extrusion load and product quality. Two renewable lubricants were analyzed (RBD palm olein and jatropha) together with an additive free paraffinic mineral oil, VG32, which acted as a reference lubricant. The experiment used a cold work plane strain extrusion apparatus that consists of a pair of taper die and a symmetrical work piece (billet). The billet material was made of annealed pure aluminum JIS-A1100 with radius of 5 mm in the deformation area. It was found that higher viscosity lubricants produced low extrusion load and friction during metal forming process with no major severe wear on product quality. Based on the results, it was proven that renewable resource based lubricants can be considered as a substitute for common lubricants used in the industry, since they present similar results with those currently applied in the industry. 

Study of Alternative Lubricants for Cold Extrusion Process of A1100 Pure Aluminum

2014 ◽  
Vol 71 (2) ◽  
Author(s):  
A. Nurul M. ◽  
Syahrullail S.
Keyword(s):  
Renewable Resources ◽  
Pure Aluminum ◽  
Cold Work ◽  
Palm Kernel ◽  
Palm Stearin ◽  
Mineral Oil ◽  
Cold Extrusion ◽  
Film Material ◽  
Ability To Act ◽  
Taper Die

Lubrication in metal forming process is very important to control wear and friction at the interface between interacting surfaces. Non-renewable resources, such as mineral oil are widely used since a beginning due to its ability to act as a supplier to the wearing contact which functions as a film material or sustains chemical transformation to become a film material. Since it is will not last for a few more decades, renewable resources had been studied in order to find an alternative lubricant with presents similar results in terms of extrusion load and product quality. Two renewable lubricants were analyzed (Palm Kernel and Palm Stearin) together with additive free paraffinic mineral oil VG460 will act as a comparison lubricant. The experiment used a cold work plane strain extrusion apparatus consisting of a pair of taper die and a symmetrical work piece (billet). The billet material was annealed pure aluminum A1100 with radius of 5mm at the deformation area. It was found that palm Palm Kernel and Palm Stearin performed slightly high extrusion load, however they show no severe wear on product surface. Based on the results, it is proven that renewable based lubricants can be considered as a substitute to common mineral based lubricants used in the industry.

scholarly journals Laser Welding of High-strength Aluminium Alloys for the Sheet Metal Forming Process

Procedia CIRP ◽  
2014 ◽  
Vol 18 ◽  
pp. 203-208 ◽  
Author(s):  
J. Enz ◽  
S. Riekehr ◽  
V. Ventzke ◽  
N. Sotirov ◽  
N. Kashaev
Keyword(s):  
Laser Welding ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Aluminium Alloys ◽  
High Strength ◽  
Forming Process ◽  
Metal Forming Process

Wrinkling Prediction and Optimization of Sheet Metal Forming Process by Numerical Simulation

2015 ◽  
Vol 818 ◽  
pp. 252-255 ◽  
Author(s):  
Ján Slota ◽  
Marek Šiser
Keyword(s):  
Numerical Simulation ◽  
Material Model ◽  
Mechanical Tests ◽  
Simulation Software ◽  
Forming Process ◽  
Part Geometry ◽  
Nominal Thickness ◽  
430 Stainless Steel ◽  
Metal Forming Process ◽  
Aisi 430

The paper deals with optimization of forming process for AISI 430 stainless steel with nominal thickness 0.4 mm. During forming of sidewall for washing machine drum, some wrinkles remain at the end of forming process in some places. This problem was solved by optimization the geometry of the drawpiece using numerical simulation. During optimization a series of modifications of the part geometry to absolute elimination of wrinkling was performed. On the basis of mechanical tests, the material model was created and imported into the material database of Autoform simulation software.

Application of the Radial Return Method to Compute Stress Increments From Mroz’s Hardening Rule

2000 ◽  
Vol 123 (4) ◽  
pp. 398-402 ◽  
Author(s):  
Sing C. Tang ◽  
Z. Cedric Xia ◽  
Feng Ren
Keyword(s):  
Metal Forming ◽  
Computing Time ◽  
Isotropic Hardening ◽  
Stress Increment ◽  
Anisotropic Hardening ◽  
Forming Process ◽  
Shell Elements ◽  
Hardening Rule ◽  
Metal Forming Process ◽  
Return Method

It is well known in the literature that the isotropic hardening rule in plasticity is not realistic for handling plastic deformation in a simulation of a full sheet-metal forming process including springback. An anisotropic hardening rule proposed by Mroz is more realistic. For an accurate computation of the stress increment for a given strain increment by using Mroz’s rule, the conventional subinterval integration takes excessive computing time. This paper proposes the radial return method to compute such stress increment for saving computing time. Two numerical examples show the efficiency of the proposed method. Even for a sheet model with more than 10,000 thin shell elements, the radial return method takes only 40 percent of the overall computing time by the subinterval integration.

Numerical and Experimental Investigations of Multistage Sheet-Bulk Metal Forming Process with Compound Press Tools

2015 ◽  
Vol 651-653 ◽  
pp. 1153-1158 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Anas Bouguecha ◽  
Milan Vucetic ◽  
Sven Hübner ◽  
Daniel Rosenbusch ◽  
...  
Keyword(s):  
Metal Forming ◽  
Solid Metal ◽  
Experimental Investigations ◽  
Metal Component ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Process Sequence ◽  
Metal Forming Process ◽  
Flange Forming

Sheet-bulk metal forming is a manufacturing technology, which allows to produce a solid metal component out of a flat sheet. This paper focuses on numerical and experimental investigations of a new multistage forming process with compound press tools. The complete process sequence for the production of this solid metal component consists of three forming stages, which include a total of six production techniques. The first forming stage includes deep drawing, simultaneous cutting and following wall upsetting. In the second forming stage, flange forming combined with cup bottom ironing takes place. In the last stage of the process sequence, the component is sized. To investigate and to improve process parameters such as plastic strain distribution, resulting dimensions and process forces, FEA is performed. Based on these results the developed process is designed.

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