Wear Prediction in Oscillating Cold Forging Processes

Groche, Peter; Schmidt, Wilhelm

doi:10.1007/s11249-020-01367-w

Cited by 4 publications

(3 citation statements)

References 16 publications

(18 reference statements)

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“…The calibration zone slides on the already formed surface during forward and return stroke. Numerical simulations show that a contact normal stress of 1200 to 1800 N/mm 2 can be found in this area [6]. Therefore, this zone is potentially strongly influenced by friction conditions and especially static friction.…”

Section: Introductionmentioning

confidence: 91%

Static Friction in Oil Lubricated Cold Forming Processes

et al. 2022

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Friction is one of the variables that have a far-reaching influence on forming processes. In the past, less attention was paid to static friction than to sliding friction in forming processes. In this paper, a test stand for the determination of static friction under load in metal forming is presented. The results are discussed using the example of an oscillating cold forming process. It could be shown that the expected influence of static friction is low in this application. Graphical abstract

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Section: Introductionmentioning

confidence: 91%

Static Friction in Oil Lubricated Cold Forming Processes

et al. 2022

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“…Due to the tight packing of the individual forming operations and the necessary components such as guides, blank holders, strippers, ejectors, etc., there is not enough space available, especially in existing tool systems. In addition, the integration of sensors must be considered in the tool design phase in order to create the necessary space and to control the properties of the tool system (e.g., rigidity of the tool system [2]). System Dynamics: As a result of the press movement, impulse-like loads are created in the forming zone, causing the system to oscillate when the tool hits the metal strip and when the product is separated from the metal strip.…”

Section: Introductionmentioning

confidence: 99%

Image based feature extraction for inline quality assurance and wear classification in high speed blanking processes

Kubik,

Molitor,

Varchmin

et al. 2023

Preprint

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Wear is one of the key factors that determine the efficiency of multi-stage processes that include blanking operations. Since wear in these processes not only causes unplanned downtime, but also directly affects product quality, inline detection of wear and its effect on product quality is of major importance. However, current quality assurance (QA) methods are limited to manual offline inspection by operators at predefined intervals, so that 100% inspection of the product and description of the state of wear is not found in industrial practice. The aim of this work is therefore to develop an optical system that enables in-line acquisition of product images and the associated control of blanking-specific quality features up to stroke rates of 300 strokes per minute (spm). In order to make the system attractive to small and medium-sized enterprises (SME), the system is designed to minimize integration and investment costs using commercially available components. By combining the system with a methodology for extracting blanking-specific features, so-called Key Performance Parameters (KPPs), the condition of the blanked surface as a relevant quality parameter is derived directly from the workpiece image. To demonstrate the transferability of the methodology to industrial applications, two use cases are investigated. In the first case, the KPPs are used directly to determine the quality of the blanked workpiece and are compared with reference measurements. Here, the KPPs are quantified with a mean absolute error of 18 µm compared to a ground truth. In the second case, the KPPs are used to build a machine learning (ML) model to estimate the wear of the blanking tool. Here, an accuracy of 92% is achieved in classifying the actual wear state.

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“…Although this method is effective, a method for designing the appropriate ironing conditions has not been established yet. Servo presses have become common in the stamping process, and a method to prevent the decrease in lubricant film thickness by re-supplying lubricant by repeatedly pulling back the punch has been proposed for forging [5,6]. The re-supplying lubricant method may be possible to increase seizure IOP Publishing doi:10.1088/1757-899X/1270/1/012018 2 resistance in ironing by thick lubricant film.…”

Section: Introductionmentioning

confidence: 99%

Increase in ironing limit of stainless steel cups with lubricants containing ceramic particles

Abe

Yamashita

Mori

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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The seizure resistance in the ironing process of stainless steel cups was improved with lubricants containing Al2O3 particles, and the ironing limit of the cups was increased. The effects of suspending different concentrations of Al2O3 particles in paraffin based oils on increasing the ironing limit of SUS430 cylindrical cups before seizure were investigated using a lapped tungsten carbide die. By containing c = 2vol% of Al2O3 particles having nominal diameter d between 0.02 to 4 micrometres in an oil with a kinematic viscosity of 500 mm2/s, the ironing limit of the cup was 8% under a punch speed of 100 mm2/s. The limit was similar to the limit using a commercial low-viscosity oil with chlorine additive. The kinematic viscosity of the base oil was reduced. In d = 0.2 μm and c = 0.5vol%, the limit of the oil more than kinematic viscosity of 180 mm2/s was similar to the limit by the commercial oil. In d = 4 μm and c = 1vol%, the limit of the oil having more than kinematic viscosity of 100 mm2/s was effective. It was found that the seizure resistance in the ironing process was improved by the proper ironing conditions with lubricants containing particles.

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Wear Prediction in Oscillating Cold Forging Processes

Cited by 4 publications

References 16 publications

Static Friction in Oil Lubricated Cold Forming Processes

Static Friction in Oil Lubricated Cold Forming Processes

Image based feature extraction for inline quality assurance and wear classification in high speed blanking processes

Increase in ironing limit of stainless steel cups with lubricants containing ceramic particles

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