Wear behavior of tribologically optimized tool surfaces for incremental forming processes
Wear behavior of tribologically optimized tool surfaces for incremental forming processes
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DOI：
10.1016/j.triboint.2016.08.028
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发表时间：
2016-12-01
影响因子：
6.2
通讯作者：
Stangier, D.
中科院分区：
文献类型：
--
作者：
Sieczkarek, P.;Wernicke, S.;Stangier, D.
成形工具的机械磨损行为是渐开线齿轮成形过程中的限制因素。这些形状简单的成形工具暴露在高成形力下。此外，作为该增量工艺的特征的必要的工件内腔限制了工具的尺寸标注。因此，成形工具的几何设计受到限制，从而导致寿命降低。工具表面上的功能结构可以通过减少接触面积、润滑剂口袋的供应以及对发生的材料流动的受控影响和调整来影响发生的加载和磨损行为。为了延长刀具的使用寿命，研究了不同的表面概念和与CrAlN PVD涂层的组合。为了提供高刀具载荷的条件，研究了一种简单的单楔成形工具的齿轮渐进成形工艺。结果表明，齿轮的磨损和粘着磨损特性，以及齿轮的破裂和裂纹的形成。后刀面上的裂纹扩展导致刀尖碎裂，从而限制了刀具的使用寿命。与基准刀具相比，结合PVD涂层的表面结构显著提高了刀具寿命84%。(C)2016爱思唯尔有限公司。保留所有权利。
The mechanical wear behavior of forming tools is the limiting factor during an incremental gear-forming process. These forming tools with a simply shaped geometry are exposed to high forming forces. Additionally, the necessary workpiece chambering, which is characteristic for this incremental process restricts the dimensioning of the tools. Thereby, the geometrical design of the forming tools is limited, which leads to a decreased lifetime. Functional structures on the tool surfaces can influence the occurring loading and wear behavior by reducing the contact area, the supply of lubricant pockets, and by a controlled influence and adjustment of the occurring material flow. For the extension of the tool's lifetime, different surface concepts and combinations with CrAlN PVD-coatings are investigated. To offer conditions with a high tool load, the investigations are focused on an incremental gear forming process with a simple one-wedge forming tool.The results show abrasive and adhesive wear characteristics, as well as outbreaks, and crack formations. The crack propagation on the flank leads to a chipping of the tool tip, hence limiting the tool life. Compared to the reference tool, a surface structure combined with a PVD-coating provides a significant increase of the tool life of 84%. (C) 2016 Elsevier Ltd. All rights reserved.