Accounting for the increase of wear in metal forming tools, it is eminent to have detailed information about the tool lifetime already during the tool design. With the wear simulation tool REDSY-developed at the Institute of Metal Forming and Casting-tool wear can be simulated qualitatively and quantitatively for sheet metal forming processes. The calculations are based on Archard's wear model, a model using contact mechanics to describe the wear behavior. In this project, a new approach to determine the wear coefficient has been developed using a simple cylindrical cup deep drawing experiment for the wear measurements. Several tool and sheet material combinations were analyzed using a five-stage progressive die tool in a precision automatic punching press in order to achieve a high wear volume in a short period of time. The wear coefficient for the respective material combination could be determined combining the experimental results with simulation. This method is verified by comparing the wear simulation results with actual measurements.
MotivationWear research in the field of sheet metal forming is becoming more and more important, as the automotive industry is using an increasing amount of high strength sheet materials for weight reduction while retaining or even increasing the crash performance of the body in white. Consequently, wear in sheet metal forming tools has an influence on the part tolerances, which can cause additional unexpected maintenance costs. Accounting for the increase of wear in metal forming tools, it is important to have detailed information about the tool lifetime before the tool is produced. That way suitable materials can be picked and maintenance intervals can be planned on a solid state of knowledge.A qualitative and quantitative knowledge about the wear behavior of metal forming tools is based on numerical simulation. Wear in metal forming is described with contact mechanics models, whereof Archard's wear model is best suitable for this application [1,2]. In this model, the wear volume W [mm 3 ] is described as dependent on the wear coefficient K [-] normal force F N [N] tool hardness H [MPa] and sliding distance s [mm]:
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