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One of the major causes for tool failure in sheet metal forming is transfer and accumulation of adhered sheet material to the tool surfaces, generally referred to as galling. In the present work, the galling resistance of several tool materials was investigated against two-phase ferritic-martensitic carbon steel under dry sliding test conditions. Tribological evaluation was carried out at different contact pressures by using a slider-on-flat-surface (SOFS) tribometer. For all selected test conditions, a consistent ranking of the materials was obtained with best performance observed for nitrogen alloyed powder metallurgy tool steel. Worst galling resistance was observed by nodular cast iron.

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In the present research, a comparison of worn surface morphologies and wear mechanisms observed for worn deep drawing dies and sheets from the automotive car body manufacturing and worn surfaces obtained by a slider‐on‐flat‐surface (SOFS) tribometer has been carried out. Abrasion and adhesion were identified as the main surface damage mechanisms on the investigated dies and sheets. Comparison of the results obtained in laboratory testing using the SOFS tribometer showed that the test method properly simulates the tribological conditions occurring in actual sheet metal forming operations. Copyright © 2007 John Wiley & Sons, Ltd.

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