The competition among sheet-metal-forming manufacturers in recent years has become more severe. Many manufacturers have survived by cutting their production costs. Increasing the formability, which could reduce the production costs, is the focus of many manufacturers and engineers. In the present research, to increase the formability over the limiting drawing ratio (LDR) in the cylindrical deep-drawing process, the application of oleophobic coating is proposed. An SUS304 (JIS standard)-stainless-steel cylindrical deep-drawn component was used as the investigated model. First, we applied the oleophobic coating in the sheet-metal-forming process, and tribology tests were carried out to examine the friction coefficients, which were reduced by approximately 60% compared with those of standard lubricant use (Iloform TDN81). Next, deep-drawing tests were performed to investigate the drawing ratio (DR). The LDR recommended in the past could be overcome, and it increased by approximately 12% with the oleophobic coating use. Finally, the deep-drawing mechanism using an extremely low friction coefficient was clarified as well. Based on these results, an oleophobic coating could be applied in the cylindrical deep-drawing process to increase the LDR. The results also clearly expose the multidisciplinary approach that combines an oleophobic coating application and the sheet-metal-forming process.
The ‘formability’ of sheet metal is a major keyword referring to process design in the sheet metal forming industry. Higher formability could reflect lower production costs and time. Many studies have been carried out to improve formability in various ways, by using the finite element method and experimental approaches. In the present research, a new zoning lubricant technique is proposed. The stainless steel SUS304 square deep drawn box is used as an investigative model. Based on the material flow analysis, we found that zoning lubricant die application could reduce the difference in material flow velocity between wall and corner zones. This material flow characteristic resulted in decreased nonconcurrent plastic deformation during the deep drawing process, as well as decreased stretching in the cup wall and the delaying of the fracture. In the present research, the design of the zoning lubricant die was strictly concerned with achieving functionality related to the friction coefficient, area of zoning, and blank-holder pressure. A smaller friction coefficient positioned in the corner zone and larger friction coefficient positioned in the wall zone are recommended. It was revealed that, by appropriate zoning lubricant die application, formability could be increased in terms of box height by approximately 7 mm or 10%.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.
hi@scite.ai
10624 S. Eastern Ave., Ste. A-614
Henderson, NV 89052, USA
Copyright © 2024 scite LLC. All rights reserved.
Made with 💙 for researchers
Part of the Research Solutions Family.