Lubricant free forming with tailored tribological conditions

在定制的摩擦条件下进行无润滑成型

• 批准号: 244843181
• 负责人: Professorin Dr.-Ing. Marion Merklein
• 金额: --
• 依托单位: Lehrstuhl für Photonische Technologien (LPT)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2013
• 资助国家: 德国
• 起止时间: 2012-12-31 至 2015-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/244843181?language=en
• 关键词: Lubricant; free; forming; tailored; tribological

Within lubricant free forming an intensive interaction of workpiece and tool surface occurs. The aim of this research project is the realization of dry forming processes by developing and applying innovative tribological systems. The challenges of dry forming such as increased friction accompanied by increased wear are met by tool based surface modifications in a tailored tool approach. In the first period of the project forming of steel sheets is investigated in a lubricant-free deep drawing process. In order to test the transferability of derived correlations to other workpiece material classes also an aluminum alloy is tested. In basic experiments under laboratory conditions the fundamental understanding of lubricant free forming is generated by the analysis and description of the occurring tribological effects. At the same time the test results serve as input values for the simulation based design of the segmented tool for manufacturing the demonstrator cup. In the FE simulation tribological relevant tool areas are identified. Subsequently, required surface properties for each tool segment are derived in an inverse approach. The requirements represent the targets for the development of tailored surface modifications. In order to guarantee reasonable wear resistance the suitability of DLC coating systems for lubricant free deep drawing is assessed. In some tool areas lubricant free forming requires an extraordinary high wear resistance of the coatings. In this regard the laser induced heat treatment of DLC coatings is investigated for the local enhancement of wear resistance. Furthermore, for the purpose of controlling the material flow tool based surface structures will be developed and applied by laser ablation. While developing the surface coatings and structures the frictional and wear behavior of the different modification types are investigated by carrying out model tests under laboratory conditions. In particular, the influences of the factors tool material, surface structure and coating on the tool behavior are quantified. For determination of the limits of dry forming process the interactions of tool behavior and occurring process loads are investigated in the laboratory tests. The derived correlations between the process loads, the surface modifications and the resulting tool behavior are used for the local adjustment of the tribological conditions within the lubricant free model process. In order to validate these correlations the friction and wear behavior of the segmented tool is determined in the deep drawing process for the investigated steel and aluminum grade. The results of the first period of the project represent the basis for qualification of tailored tribological systems for the application in lubricant free forming processes.

在无润滑成形中，工件和工具表面发生强烈的相互作用。该研究项目的目的是通过开发和应用创新的摩擦学系统来实现干式成型工艺。干式成形的挑战，如增加的摩擦伴随着增加的磨损，是通过定制工具方法中的基于工具的表面改性来满足的。在项目的第一阶段，研究了无润滑剂深拉工艺中的钢板成形。为了测试导出的相关性到其他工件材料类别的可转移性，还测试了铝合金。在实验室条件下的基础实验中，通过对发生的摩擦学效应的分析和描述，对无润滑剂成形产生了基本的理解。同时，测试结果用作用于制造演示杯的分段工具的基于模拟的设计的输入值。在FE模拟中，确定了摩擦学相关工具区域。随后，每个工具段所需的表面特性推导出在一个逆的方法。这些要求代表了定制表面改性开发的目标。为了保证合理的耐磨性，DLC涂层系统的无润滑拉深的适用性进行了评估。在某些刀具领域，无润滑剂成形要求涂层具有极高的耐磨性。在这方面，DLC涂层的激光诱导热处理的耐磨性的局部增强进行了研究。此外，为了控制材料流动的目的，基于工具的表面结构将通过激光烧蚀来开发和应用。在研制表面涂层和结构的同时，通过在实验室条件下进行模型试验，研究了不同改性类型的摩擦磨损性能。特别地，量化了刀具材料、表面结构和涂层等因素对刀具性能的影响。为了确定干式成形工艺的极限，在实验室试验中研究了工具行为和发生的工艺载荷的相互作用。推导出的过程负载，表面改性和由此产生的工具行为之间的相关性用于局部调整的摩擦学条件内的润滑剂自由模型过程。为了验证这些相关性的摩擦和磨损行为的分段工具，确定在深拉过程中的调查钢和铝等级。该项目第一阶段的结果代表了无润滑成形工艺中应用的定制摩擦学系统的资格认证基础。