In this paper, some technological problems (e.g. low drawability, high susceptibility to galling, spring-back) occurring in the sheet-titanium forming process are discussed. A numerical simulation of the stamping process was carried out with the Adina System v.8.3 based on the finite element method. The effects of friction, the holding-down force and tool geometry on the course of the stamping process were analysed. The mechanical and technological material data needed for the calculations were determined experimentally. The friction coefficients for the frictional pair: ”titanium – tool steel” for different lubricants and antiadhesive layers determined in the “strip drawing” test were found. The role played by lubrication and antiadhesive layers in preventing titanium “build-ups” on the tools is presented. The calculated results were then confirmed experimentally.

Sheet metal forming processes allow for production of lightweight and durable goods. For this reason, drawing operations have been widely used across the automotive, aviation and construction industries and for production of various components of machines. Despite the popularity of deep-drawing steel sheet metal, non-ferrous materials, such as aluminium, magnesium and titanium are also used for such purposes. Titanium materials seem to be particularly attractive due to a beneficial ratio of strength to density and excellent corrosion resistance in the most of technological environments. However, titanium and its alloys belong to a group of materials with low tribological properties and tendencies for galling and build-up of layers of the deformed material on the tool surface. Therefore, this study will discuss the results of the investigations concerning selection of technological lubricants based on vegetable oils used for the operation of forming of sheet metal made of commercially pure titanium (Grade 2). The focus of the experiment is on lubricants based on vegetable oils i.e. rapeseed oil, sunflower oil and olive oil. The main lubricating additive was boric acid and stearic acid. The study presents the results of the determination of friction coefficient during a strip drawing test.

Sheet metal forming belongs to one of the most important technologies enabling the production durable but quite lightweight metal parts. The quality of the drawn parts depends on the deformed sheet metal, applied forming technology and process parameters, such as contact pressure, relative velocity, temperature or lubrication. The forming of steel (1.4021) parts using benign lubricant is analysed. The paper proposes replacing conventional mineral/synthetic lubricants with ones based on vegetable oils and boric acid. The effectiveness of the lubricants was assessed in laboratory strip drawing and cupping tests, and in production. An oil-based lubricant with an additive of boric acid is very effective in reducing frictional resistance and protecting the forming tools against galling. Graphic abstract

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Forming of titanium sheets, especially titanium alloy sheets, is very difficult due to low drawability caused by a high ratio of the yield point to the tensile strength Re/Rm, usually more than 90%. Although drawability of titanium sheets can be enhanced by forming at elevated temperatures it is avoided due to the high costs and difficulties associated with the operation of the process. Therefore the authors have developed an unconventional stamping method allowing for forming of almost unworkable materials at ambient temperature, such as Ti6Al4V titanium alloy. The paper presents both numerical simulation and experimental results of the stamping process using a device specially designed for this purpose.