A large quantity of lubricant waste has become a very serious environmental issue. For the zero emission of lubricants, dry deep drawing is efficient; however, it is generally very difficult to apply it to metal sheets. As one of the most promising methods, the use of ceramic tools is proposed because of their high tribological properties. However, the workability of the ceramic tools is poor. Therefore, the forming of a complex shape is difficult and even the forming of a simple shape is expensive. Thus, the use of electroconductive ceramic tools in this research is proposed. The electroconductive ceramic tools can be formed by electrical discharge machining methods (e.g., wire and die milling electric discharge machining methods). Therefore, the shape of a metal mold can easily be molded. Using an electroconductive ceramic as a plastic forming tool, a high drawability was confirmed and dry deep drawing of 10,000 times was achieved. The surface roughness of a dry deep drawing cup was as large as that of a non-dry (oil) deep drawing cup.
The large quantity of lubricant waste has become a very serious environmental issue. To realize zero emission of lubricants, dry deep drawing is attractive, but it is very difficult to apply to metal sheets. As one of the most promising methods without lubricant, the use of ceramic tools was proposed because of their high tribological properties. However, the workability of ceramics in tool preparation is inferior to that of alloy tool steel. Therefore, the forming of complex shapes is difficult. We propose the use of electroconductive ceramics for the tool in this study. The electroconductive ceramics can be formed by electrical discharge machining (die-milling electric discharge, etc). Therefore, the shape of the press die can be easily molded. In the previous paper, 10,000 repetitions of dry cylindrical deep drawing were achieved with the electroconductive ceramic tool. In this study, deep drawing of a rectangle, which is a more complex shape, was examined. As a result, 10,000 repetitions of dry rectangular deep drawing were achieved. The surface roughness of a dry-deep-drawn cup was equal to or better than that of a non-dry (oil)-deep-drawn cup. Moreover, it was confirmed that a complex shape of the press die could be easily molded.
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