Application of Calcium Carbonate as Green Lubricant Additive in Sheet Metal Forming

Abstract

The application of calcium carbonate particles as a green lubricant additive for sheet metal forming processes has been evaluated. Different particle sizes were tested, along with different concentrations of particles in a lubricant that typically does not perform well by itself. The lubricant mixtures were tested under pin-on-disc, four-ball, and bending-under-tension test conditions. The results of the different tribological tests were compared to determine whether standard tests, such as the four-ball test, could predict lubricant performance under sheet metal forming conditions. The application of any concentration of particles was shown to be beneficial to the lubricant performance in terms of wear resistance even though friction increased when calcium carbonate particles were added to the base paraffin oil. Small particles (40 nm) exhibited better performance than large particles (2 μm).

Application of CaCO₃ as Anti-Friction Lubricant Additive to Improve Robustness in Sheet Metal Forming of High-Strength Aluminum

“…A base mixture of CaCO 3 particles (commerically known as PolyPlex 2 [17]) with an average diameter of 2 µm, and paraffin oil was diluted by adding more paraffin oil to arrive at a nominal mixture having a concentration of 40 mass% CaCO 3 . The base mixture was prepared as part of other work [13], by first dissolving Tween60 [18] in paraffin oil at 1,900 rpm using a high-speed dissolver and then dispersing the particles in the oil mixture at 3,500 rpm to a concentration of more than 40 mass% CaCO 3 . In all tests, approximately 10 g/m 2 of lubrication was applied to the tools and not the workpiece as this gives an indication of the resistance of the lubricant to being wiped off the tool.…”

“…This is often accomplished through the use of additives, such as viscosity index improvers or antioxidants that help to keep the lubricant stable as the temperature increases [11]. The use of solid particles as lubricant additives has also been shown to improve anti-seizure performance [12] and stabilize the tribo-system [13]. The effect of including solid particles that are not affected by the temperature is illustrated in Fig.…”

Analysis of the Effectiveness of Technological Lubricants with the Addition of Boric Acid in Sheet Metal Forming

“…They have a greater tendency to flow out of the frictional pair, which requires more frequent application and the introduction of thickening agents. Recently, scientists have evaluated technological lubricants in terms of their positive effect on sheet drawability, while also taking into account their impact on the environment [ 11 , 12 , 13 ]. According to [ 9 ], the problem is that, unlike machine lubrication, where the lubricant works in a closed circuit, metal forming involves a so-called open friction node, which results in a much higher consumption of technological lubricant.…”

The influence of Particle Hardness on Wear in Sheet Metal Forming

“…However, the particle also affected the stability of the lubrication mechanism in a deleterious way, which lead to increased wear after some time. In other work [10], the efficacy of CaCO3 particles of two sizes for improving tribological conditions was evaluated. The particles were added to a base oil, along with a surfactant to ensure proper dispersion, and then tested by applying pin-on-disc testing, four-ball testing, and bending-under-tension testing.…”