Off-line testing of multifunctional surfaces for metal forming applications

Godi, Alessandro; Grønbæk, J.; Chiffre, Leonardo De

doi:10.1016/j.cirpj.2015.06.001

Cited by 6 publications

(6 citation statements)

References 19 publications

(34 reference statements)

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“…In order to ensure the successful design of such tailored tool surfaces, it is important to understand the influence of surface texture parameters on friction and lubrication in metal forming. Manufacturing of the tailored tool surfaces into a table mountain-like structure with flat plateaus and neighbouring flat bottomed valleys can be obtained by combined grinding, milling, and polishing of tools [12,13]. A small pocket angle towards the workpiece surface facilitates escape of the trapped lubricant in the pockets, which increases the tool life [14].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

2017

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While texturing of workpiece surfaces to promote lubrication in metal forming has been applied for several decades, tool surface texturing is rather new. In the present paper, tool texturing is studied as a method to prevent galling. A strip reduction test was conducted with tools provided with shallow, longitudinal pockets oriented perpendicular to the sliding direction. The pockets had small angles to the workpiece surface and the distance between them were varied. The experiments reveal that the distance between pockets should be larger than the pocket width, thereby creating a topography similar to flat table mountains to avoid mechanical interlocking in the valleys; otherwise, an increase in drawing load and pick-up on the tools are observed. The textured tool surface lowers friction and improves lubrication performance, provided that the distance between pockets is 2-4 times larger than the pocket width. Larger drawing speed facilitates escape of the entrapped lubricant in the pockets. Testing with low-to-medium viscosity oils leads to a low sheet roughness on the plateaus, but also local workpiece material pick-up on the tool plateaus. Large lubricant viscosity results in higher sheet plateau roughness, but also prevents pick-up and galling.

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Section: Introductionmentioning

confidence: 99%

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

2017

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“…material leads to a high load on the tool during forming, and as a result, the problem of galling becomes more pronounced [15][16][17].…”

Section: Rt~400mentioning

confidence: 99%

Galling phenomena in metal forming

Dohda

Yamamoto

et al. 2020

Friction

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Galling phenomena in metal forming not only affect the quality of the engineered surfaces but also the success or failure of the manufacturing operation itself. This paper reviews the different galling conditions in sheet and bulk metal forming processes along with their evolution and the effects of temperature on galling. A group of anti-galling methods employed to prevent galling defects are also presented in detail. The techniques for quantitatively measuring galling are introduced, and the related prediction models, including friction, wear, and galling growth models, are presented to better understand the underlying phenomena. Galling phenomena in other processes similar to those occurring in metal forming are also examined to suggest different ways of further studying galling in metal forming. Finally, future research directions for the study of galling in metal forming are suggested.

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“…The generated frictional force causes wear on tools and increases the total energy required to complete the process. It is estimated that around 30% of the energy generated globally is lost due to friction, so developed countries allocate approximately 5% of their GDP to develop strategies to minimize friction [1].…”

Section: Introductionmentioning

confidence: 99%

Tool surface texturing by shot peening: initial results and lessons learned

de Argandoña,

Mendez,

Mendiguren

et al. 2024

IOP Conf. Ser.: Mater. Sci. Eng.

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Abrasive and adhesive wear is a major issue in sheet metal forming processes. Although different solutions exist to reduce its impact, there is still room for progress. Surface texturing presents a big potential for tribological behaviour improvement by introducing oil retention voids on the surface. However, the economic efficiency of the surface functionalization is paramount for its implementation in industrial processes. In the present study, a widely known technology, shot peening, is applied for the creation of the voids. A grinding+polishing process is then applied to ensure a flat load bearing area. The textures are generated in 1.2379 tool steel blocks hardened at 60 HRc that emulate the tool. Different shot peening strategies are evaluated by carrying out strip drawing tests with AA5754H111 aluminium alloy sheets. Contact pressures up to 25 MPa are applied and the adhesive wear reduction potential is evaluated. First results point out the potential of this solution although the applied shot peening strategy needs to be carefully defined.

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Off-line testing of multifunctional surfaces for metal forming applications

Cited by 6 publications

References 19 publications

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

Galling phenomena in metal forming

Tool surface texturing by shot peening: initial results and lessons learned

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