A comparative friction study of tooling dies with a simple internal cylindrical geometry has been performed. The purpose of the experiment consist of studying the influence of the surface characteristics of tooling dies on the frictional behaviour in a micro bulk forming operation. This research will seek to contribute with knowledge in the field of the category of structural size effects. By evaluating and benchmarking three different surface topographies, in an Ø1 and an Ø2 millimetre cylindrical forming-die, it is expected that frictional performance and forming limits can be evaluated, with the option of extracting general guidelines for evaluation of surface characteristics for dies utilized for micro-forming. The DCE test will be supported by numerical analysis in order to determine the friction factor.
In metal forming processes tribology plays a significant role for process feasibility and tool lifetime. Boundary and mixed lubrication conditions are predominant in metal forming processes. Hence the appearing real contact area which is mainly influenced by the topography of tool and workpiece has a major impact on friction conditions. For an improved understanding of friction at the interface between tool and workpiece, the flattening behavior of idealized asperities under boundary lubrication conditions is investigated by applying a translucent tool. Various liquid lubricants have been used. It has been revealed that the usage of certain lubricants leads to higher resistance of the asperity against flattening which would be in favor of reduced friction. Topography analysis and finite element simulations have been performed in order to get more insight into the mechanisms leading to this effect. The findings have been transferred to real topographies by micro upsetting tests with ground surfaces.
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