The application of calcium carbonate particles as a green lubricant additive for sheet metal forming processes has been evaluated. Different particle sizes were tested, along with different concentrations of particles in a lubricant that typically does not perform well by itself. The lubricant mixtures were tested under pin-on-disc, four-ball, and bending-under-tension test conditions. The results of the different tribological tests were compared to determine whether standard tests, such as the four-ball test, could predict lubricant performance under sheet metal forming conditions. The application of any concentration of particles was shown to be beneficial to the lubricant performance in terms of wear resistance even though friction increased when calcium carbonate particles were added to the base paraffin oil. Small particles (40 nm) exhibited better performance than large particles (2 μm).
Punching and blanking processes are characterized by severe tribological conditions due to the creation of virgin surfaces, which are highly prone to develop pick-up of workpiece material on the punch surface. Hazardous forming lubricants are, therefore, commonly used in punching and blanking processes for avoidance of wear induced process deviations such as diminished surface quality, reduced dimensional accuracy and reduced tool life. The present study characterizes the function and performance of lubricants used for punching and blanking operations for assessment of the tribological lubricant properties necessary for adaption of environmentally friendly lubricant alternatives.Analysis of the tribochemical properties of the studied lubricants indicate that an applicable temperature range and a high load bearing capacity are central lubricant properties necessary for ensuring sufficient lubricating ability for punching and blanking operations.
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