The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

Abstract

While texturing of workpiece surfaces to promote lubrication in metal forming has been applied for several decades tool surface texturing is rather new. In the present paper tool texturing is studied as a method to prevent galling. Adopting a strip reduction test longitudinal pocket geometries oriented perpendicular to the sliding direction, with shallow pocket depth, small pocket angle to the workpiece surface and varying distance between pockets are investigated. The experiments reveal that the distance between pockets should be larger than the pocket width thereby creating a topography similar to flat table mountains to avoid mechanical interlocking in the valleys; otherwise an increase in drawing load and pick-up on the tools is observed. The textured tool surface lowers friction and improves lubrication performance provided that the distance between pockets is 2-4 times larger than the pocket width. Larger drawing speed facilitates escape of the entrapped lubricant in the pockets. Testing with low to medium viscosity oils leads to a low sheet roughness on the plateaus but also local workpiece material pick-up on the tool plateaus. Large lubricant viscosity results in higher sheet plateau roughness but also prevents pick-up and galling.