The Use of Non-Edible Green Oils to Lubricate DC04 Steel Sheets in Sheet Metal Forming Process

Abstract

Lubrication is a basic and relatively effective way to reduce friction in sheet metal forming operations. The drive to eliminate synthetic and mineral oils, which are difficult to recycle, from the manufacturing process has opened up opportunities for the use of vegetable-based bio-lubricants. This article presents a comparison of the lubrication performance of two non-edible oils (karanja and moringa) with the most frequently tested edible oils (sunflower and rape-seed). Deep drawing quality low-carbon steel sheets DC04, commonly used in the automotive industry, were used as the test material. Friction tests were carried out under various lubricants and normal pressures in the range between 3 and 12 MPa using the strip drawing test. Furthermore, a study was also made of the effect of a change in the surface topography and the mechanical properties of the sheet metal due to plastic deformation resulting from friction. It was found that under the most favorable lubrication conditions (sample pre-strain 21%, nominal pressure 6 MPa), karanja oil reduced the coefficient of friction by approximately 33%. Both non-edible lubricants provided the best lubrication when testing samples pre-strained at 7% under the whole range of nominal pressures. It was also revealed that in the case of the smallest pre-straining of the specimens (7%), karanja oil was the most effective within nominal pressures of 3–6 MPa, while at higher pressures (9–12 MPa), the moringa oil lowered the value of the coefficient of friction to a greater extent.

The Comparison of the Multi-Layer Artificial Neural Network Training Methods in Terms of the Predictive Quality of the Coefficient of Friction of 1.0338 (DC04) Steel Sheet

“…Table 1. Kinematic viscosity and density of oils tested, prepared on the basis of [33,45]. The value of the pulling force of the sheet metal strip was measured using the testing machine's measuring system.…”

“…Table 1. Kinematic viscosity and density of oils tested, prepared on the basis of [33,45]. Three sets of countersamples with different surface roughness values were tested.…”

“…Adamus et al [32] developed environmentally friendly methods for applying H3BO3 to a metal sheet by spraying it onto a thin layer of rapeseed oil that had been previously applied to the metal sheet surface. Trzepieci ński et al [33] tested the lubrication efficiency of non-edible oils with the most frequently tested edible oils (sunflower and rapeseed) in a steel-steel contact pair. It was found that the lubrication efficiency of the oils tested depends on the contact pressure and deformation of the sheet metal.…”

Application of categorical boosting to modelling the friction behaviour of DC05 steel sheets in strip drawing test

“…The lubricating substances used, due to the various parameters they must meet, are selected appropriately depending on the type of oil (natural oil, mineral oil, synthetic oil). (Carcel et al, 2005;Trzepieciński et al, 2022) and its kinematic viscosity (Bay et al, 2008;Lee et al, 2002). Another way to reduce friction in the deep drawing process is to properly select the material from which the tools are made (Kim et al, 2008;Shisode et al, 2021).…”

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.…”