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1
Introduction
2
Friction Law
N
= =
F
F = Frictional force
N = Normal force
Area (A)
= Frictional shear stress
= Normal stress
3
Stribeck curve showing onset
of various lubrication
mechanisms = lubricant viscosity;
v = sliding velocity;
p = normal pressure;
= coefficient of friction.
4
Various Lubrication Mechanism
a) Thick Film
(not realistic for
stamping)
b) Thin Film
(rarely seen in
stamping)
(Sources: Pax Products, Inc.)
5
Factors Influencing Friction and
Lubrication
6
Evolution of Tool Wear (Galling)
7
Lubrication process with oil-
based (wet) lubricant
Three important factors such as Cost, Performance
and Compatibility (with different materials and post-
processes) should be considered to select stamping
lubricants.
Additional Degreasing
Pre-Oiling Oiling (optional)
Decoiling and (optional) (optional)
cutting
Stacking
Deep Drawing +
Blanks
subsequent
(dry or
blanking
pre-oiled)
operations
8
Lubrication Process with Dry-
Film Lubricants
Deep Drawing +
Decoiling / Recoiling Decoiling subsequent blanking
with Lube coating by and cutting Stacking operations
immersion or spraying Blanks
Hot bath
9
Various Tests for Evaluating
Stamping Lubricants
10
Evaluation of Lubricants
Strip Drawing Test
In this test a strip is drawn between two opposing flat dies that are wider
than the strip. The coefficient of friction is given by
=F/2P
11
Stamping (Draw Bead) Test
Pressure
Pull hydraulic Force
gauge
cylinder transducer
BHF
hydraulic
cylinder
Die location
Jaws
13
Stamping (Draw Bead) Test
Binder holder force Binder holder force
Pulling force (BHF) (BHF)
(measured)
14
Twist Compression Test
15
TCT for Evaluation of Galling
r = 12.7 mm
Tool
surface
Galling
Galling 0 Galling 3
16
Cup Drawing Test (CDT)
12 inch Initial
blank
6 inch
Deep
drawn cup
17
Principle of CDT
As blank holder pressure (Pb) increases, frictional stress ()
increases based on Coulombs law.
19
Effects of Deformation Heat on
Lubricants
Simulation parameters
Punch diameter = 152.4 mm
Sheet diameter = 304.8 mm
Punch velocity = 70 mm/sec
BHF = 300 KN
20
Test Results of Cup Drawing
Shorter Better
perimeter lubricant
21
Strip Drawing Test (SDT)
The strip drawing test (SDT) was developed to test the higher grades of AHSS
(DP780, TRIP780 and DP980), because the limited formability of these steels
makes the deep drawing test difficult to conduct.
22
Strip Drawing Test
Dimensions of strip:
Length = 356 mm
Width = 25 mm
23
SDT for Evaluating Lubricants
with AHSS
Testing parameters Descriptions
24
SDT for Evaluating Lubricants
with AHSS
25
SDT for Evaluating Lubricants
with AHSS
26
Summary of Lubrication and
Friction
Good lubrication is crucial to form the part
successfully.
Friction at sheet-die interface is affected by the
lubricant, die material and coating, surface finish of
the sheet and die, and process conditions
(temperature, forming speed and contact pressure)
There are several methods to evaluate the
performance of lubricants.
Cup draw and strip draw tests are most practical and
they emulate the lubrication conditions existing in
production.
27
Questions & Contacts
Taylan Altan Hyunok Kim
614.292.5063 614.688.5239
altan.1@osu.edu hkim@ewi.org