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Micro-structuring and macro-structuring of deep drawing tools for dry forming condition

干成形条件下拉深工具的微观结构和宏观结构

基本信息

批准号：
244947573
负责人：
Professor Dr.-Ing. Eckhard Beyer
金额：
--
依托单位：
Professur für Formgebende Fertigungsverfahren
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 2019-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/244947573?language=en
关键词：
Micro structuring macro deep drawing

项目摘要

Large friction forces in forming processes reduce the process limits. Generally, lubricants are therefore used to reduce friction and enlarge the process window. However, the technological advantages of lubricants are accompanied by negative economic and ecological effects. Therefore, the elimination of lubricants from deep drawing processes by means of an integrated concept of a protective coating and micro- and macro structuring of the tool is studied and analysed during this project. Within the first phase, the different technologies of the integrative approach were fundamentally analysed and the deep-drawing process with tool structuring was experimentally verified. The general feasibility was demonstrated for axially symmetric parts. In the second funding period, the process principle has been further improved. For a time efficient process design an analytical model has been developed describing the influence of input parameters on the risk of wrinkling and bottom cracks. Furthermore, a feasibility study regarding high-strength steels indicated additional advantages of a macro-structured deep drawing process over standard processes. The reduction of friction forces was pursued by investigating coating technology and micro-structuring of tools and the wear behaviour of coated and structured surfaces and the interaction with blank and tool surface were investigated. All technologies were transferred to the design of a modular tool for non axially symmetric parts. Based on these results, the third research phase has the goal to implement an industrially relevant lubricant free deep drawing process for complex parts and high strength materials. The main approach remains an integrative application of different processes in the areas of macro-structuring, coating and micro-structuring. The enhancement of the macro-structuring into three-dimensional geometries is a key factor, because it allows the direct control of the material flow in tangential and radial direction, and therefore the systematic adjustment of stresses as well as bending and unbending to specifically set part characteristics. An adjusted semi-analytical model is used for designing the macro-structures and choosing process parameters. The corresponding high requirements of the forming process regarding friction and wear of the tools will be addressed with a combined approach of coating and micro-structuring. The goal is to improve on previous results by adjusting the coating and structuring processes. Specifically, a new coating with a fluor modified ta-C layer will be implemented and the chromium bonding layer will be substituted by a nitration process. Additionally, the DLIP process will adjusted by shortening pulse times and homogenising the laser beam in order to improve the quality of the micro-structure while minimising negative effects on the substrate. All technologies will be integrated and verified using the modular deep drawing tool from the second funding phase.

成形过程中的大摩擦力降低了工艺极限。因此，通常使用润滑剂来减少摩擦并扩大工艺窗口。然而，润滑剂的技术优势也伴随着负面的经济和生态效应。因此，在本项目中，通过保护涂层和刀具的微观和宏观结构的综合概念，研究和分析了在拉深过程中消除润滑剂的方法。在第一阶段中，从根本上分析了一体化方法的不同技术，并对工具结构拉深过程进行了实验验证。对于轴对称零件，论证了该方法的一般可行性。在第二个资助期，程序原则得到了进一步完善。为了及时有效地进行工艺设计，建立了一个分析模型，描述了输入参数对起皱和底部裂纹风险的影响。此外，一项关于高强度钢的可行性研究表明，与标准工艺相比，宏观结构深冲工艺具有额外的优势。通过研究涂层工艺和刀具的微观结构，研究了涂层表面和结构表面的磨损行为以及与毛坯和刀具表面的相互作用，以期达到降低摩擦力的目的。所有技术都转移到了非轴对称零件的模块化工具的设计上。基于这些结果，第三研究阶段的目标是实现一种具有工业意义的复杂零件和高强度材料的无润滑剂拉深工艺。主要方法仍然是在宏观结构、涂层和微观结构领域综合应用不同的工艺。将宏观结构增强为三维几何结构是一个关键因素，因为它允许直接控制材料在切向和径向的流动，从而系统地调整应力以及弯曲和不弯曲，以特定地设置零件特性。调整后的半解析模型用于宏观结构的设计和工艺参数的选择。将采用涂层和微结构相结合的方法来解决成形工艺对刀具的摩擦和磨损的相应的高要求。目标是通过调整涂层和结构工艺来改善以前的结果。具体地说，将实施一种新的涂层，该涂层具有氟修饰的Ta-C层，并将用氮化工艺取代铬粘结层。此外，DLIP工艺将通过缩短脉冲时间和均匀激光光束来调整，以提高微结构的质量，同时将对衬底的负面影响降至最低。所有技术都将使用第二个供资阶段的模块化深拉深工具进行整合和验证。