Tribosystems for cold forming processes based on volatile lubricants and laser structured surfaces

大多数金属成形过程使用基于矿物油的润滑剂作为中间介质，以减少摩擦和磨损。然而，这些润滑剂可能含有有毒添加剂，并且成形的部件需要在进一步的工艺步骤中进行清洁，这是非常耗时和昂贵的。在前两个资助期间，引入了一种用于金属成形过程的创新环保润滑系统。液态二氧化碳和气态氮被用作挥发性润滑剂介质。单次成形过程证明了该新型摩擦学系统在干式金属成形过程中的适用性。第三个资助期的目标是证明这种新的摩擦学系统在干金属成形过程中的实用性。因此，我们将展示新的摩擦学系统在耐久性运行中的成形过程的适用性。对于这个演示，有必要确保过程的稳定性。为了保证过程的稳定性，对新型摩擦学系统进行优化是十分必要的。在这个复杂的摩擦学系统中，更深入地了解摩擦和磨损机制是优化的基础。此外，了解在成形过程中挥发性润滑剂介质逸出的物理机制也很重要。高精度和高质量的微钻孔是确保工艺稳定性的必要条件。精确钻孔无任何毛刺，保证挥发性润滑剂介质的稳定和可重复流动，避免任何额外的摩擦。确保挥发性润滑介质均匀分布的表面结构的产生是提高工艺稳定性的另一个步骤。这种新的摩擦学系统的实际意义将通过形成具有增加附着力倾向的额外金属板材料来显示。在这种情况下，摩擦学系统需要适应，以确保基本体和抗体的分离，并减少和适应在成形过程中的摩擦。在不同的研究所中，将实现以下步骤：1)考虑到另一种金属板材材料，在理解摩擦学系统方面取得进展。2)对现有摩擦学系统进行优化。用局部适应的摩擦学系统研究和扩展成形过程耐久性运行中的过程稳定性。

Most metal forming processes use lubricants based on mineral oils as an intermediate medium to reduce friction and wear. However, These lubricants may contain toxic additives and the formed parts need to be cleaned for further process steps which is very time consuming andexpansive. During the first two funding periods an innovative and environment friendly lubrication system for metal forming processes was introduced. Liquid carbon dioxide and gaseous nitrogen are being used as volatile lubricant media. The suitability of this newtribological system for dry metal forming processes was demonstrated by single forming processes. The goal for the third funding period is to demonstrate the usability of this new tribological system for dry metal forming processes with a practical orientation. Therefore we will Show the suitability of the new tribological system for forming processeswithin endurance runs. For this demonstration it is necessary to ensure process stability. For the purpose of process stability it is essential to optimize the new tribological system. A deeper understanding of the friction and wear mechanisms within thiscomplex tribological system serves as a basis for optimization. Furthermore it is important to understand the physical mechanisms during the escape of the volatile lubricant media during the forming process. Micro drillings of highest precision and quality are necessaryto ensure process stability. Precise drillings without any Burr guarantee a stable and reproducible flow of the volatile lubricant media and avoid any additional friction. The generation of Surface structures that ensure a homogeneous distribution of the volatilelubrication media are an additional step towards an increased process stability. The practical relevance of this new tribological system will be shown by forming additional metal sheet materials with increased adhesion tendency. In this case the tribological system needs to beadapted to ensure the separation of the basic body and the antibody and to reduce and adapt friction during the forming process. Within the different institutes the following steps will be realized: 1) advancement in understanding the tribological system taking anothermetal sheet material into account. 2) Optimization of the current tribological system. 3) Investigation and extension of process stability within endurance runs of forming processes with a locally adapted tribological system.