Dry metal forming: Definition, chances and challenges

Vollertsen, Frank; Schmidt, Florian

doi:10.1007/s40684-014-0009-0

Cited by 108 publications

(43 citation statements)

References 26 publications

(19 reference statements)

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“…It provides the possibility to improve production technology regarding environmental and economic aspects. State of research in dry metal forming is based on laboratory conditions and at this point, it is not possible to exert dry metal forming in industrial mass production [1].…”

Section: Introductionmentioning

confidence: 99%

Investigations on dry sliding of laser cladded aluminum bronze

et al. 2016

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-The aim of this study was to investigate the tribological behaviour of laser cladded aluminum bronze tool surfaces for dry metal forming. In a first part of this work a process window for cladding aluminum bronze on steel substrate was investigated to ensure a low dilution. Therefore, the cladding speed, the powder feed rate, the laser power and the distance between the process head and the substrate were varied. The target of the second part was to investigate the influence of different process parameters on the tribological behaviour of the cladded tracks. The laser claddings were carried out on both aluminum bronze and cold work tool steel as substrate materials. Two different particle sizes of the cladding powder material were used. The cladding speed was varied and a post-processing laser remelting treatment was applied. It is shown that the tribological behaviour of the surface in a dry oscillating ball-on-plate test is highly dependent on the substrate material. In the third part a deep drawing tool was additively manufactured by direct laser deposition. Furthermore, the tool was applied to form circular cups with and without lubrication.

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Section: Introductionmentioning

confidence: 99%

Investigations on dry sliding of laser cladded aluminum bronze

et al. 2016

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“…A new green technology in mass production can be realised by avoiding lubricants. Thereby process steps in production as cleaning, environmental impacts, the demand of oil in production and avoidable health burden could be reduced [1]. Forming metal without lubrication causes a direct contact between the sheet and the tool, which results in intensive mechanical interaction.…”

Section: Introductionmentioning

confidence: 99%

Dry metal forming of high alloy steel using laser generated aluminum bronze tools

Freiße

Köhler

Seefeld

et al. 2015

MATEC Web of Conferences

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Abstract. Regarding the optimization of forming technology in economic and environmental aspects, avoiding lubricants is an approach to realize the vision of a new green technology. The resulting direct contact between the tool and the sheet in non-lubricated deep drawing causes higher stress and depends mainly on the material combination. The tribological system in dry sliding has to be assessed by means on the one hand of the resulting friction coefficient and on the other hand of the wear of the tool and sheet material. The potential to generate tailored tribological systems for dry metal forming could be shown within the investigations by using different material combinations and by applying different laser cladding process parameters. Furthermore, the feasibility of additive manufacturing of a deep drawing tool was demonstrated. The tool was successfully applied to form circular cups in a dry metal forming process.

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“…Forming these stronger steels has required higher forces which has accelerated tool wear rates. This issue is exacerbated when coupled with the push for industry to move away from traditional stamping lubricants to reduced lubrication and unlubricated stamping for environmental and economic reasons [1]. As a result, research into and the development of real-time process monitoring to assess tool condition and lubrication has become increasingly important.…”

Section: Introductionmentioning

confidence: 99%

Using stamping punch force variation for the identification of changes in lubrication and wear mechanism

Voss

Pereira

Rolfe

et al. 2017

J. Phys.: Conf. Ser.

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Abstract. The growth in use of Advanced High Strength Steels in the automotive industry for light-weighting and safety has increased the rates of tool wear in sheet metal stamping. This is an issue that adds significant costs to production in terms of manual inspection and part refinishing. To reduce these costs, a tool condition monitoring system is required and a firm understanding of process signal variation must form the foundation for any such monitoring system. Punch force is a stamping process signal that is widely collected by industrial presses and has been linked closely to part quality and tool condition, making it an ideal candidate as a tool condition monitoring signal. In this preliminary investigation, the variation of punch force due to different lubrication conditions and progressive wear are examined. Linking specific punch force signature changes to developing lubrication and wear events is valuable for die wear and stamping condition monitoring. A series of semi-industrial channel forming trials were conducted under different lubrication regimes and progressive die wear. Punch force signatures were captured for each part and Principal Component Analysis (PCA) was applied to determine the key Principal Components of the signature data sets. These Principal Components were linked to the evolution of friction conditions over the course of the stroke for the different lubrication regimes and mechanism of galling wear. As a result, variation in punch force signatures were correlated to the current mechanism of wear dominant on the formed part; either abrasion or adhesion, and to changes in lubrication mechanism. The outcomes of this study provide important insights into punch force signature variation, that will provide a foundation for future work into the development of die wear and lubrication monitoring systems for sheet metal stamping.

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Dry metal forming: Definition, chances and challenges

Cited by 108 publications

References 26 publications

Investigations on dry sliding of laser cladded aluminum bronze

Investigations on dry sliding of laser cladded aluminum bronze

Dry metal forming of high alloy steel using laser generated aluminum bronze tools

Using stamping punch force variation for the identification of changes in lubrication and wear mechanism

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