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

大多数金属成形工艺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的添加剂，并且成形的零件需要进行清洁以进行进一步的工艺步骤，这非常耗时和膨胀。在前两个资助期内，为金属成形工艺引入了一种创新的环保润滑系统。液态二氧化碳和气态氮被用作挥发性润滑介质。通过单次成形试验证明了该摩擦学系统对金属干式成形工艺的适用性。第三个资助期的目标是展示这种新型摩擦学系统在干式金属成形工艺中的实用性。因此，我们将展示新的摩擦学系统在耐久性运行中的成形工艺的适用性.对于该演示，有必要确保过程稳定性。为了保证工艺稳定性，必须优化新的摩擦学系统。深入了解这个复杂的摩擦学系统中的摩擦和磨损机理是优化的基础。此外，重要的是要了解在形成过程中挥发性润滑剂介质逸出期间的物理机制。最高精度和质量的微钻孔是确保工艺稳定性所必需的。无毛刺的精确钻孔保证了挥发性润滑介质的稳定和可重复流动，并避免了任何额外的摩擦。表面结构的生成确保了挥发性润滑介质的均匀分布，这是提高工艺稳定性的又一步骤。这种新的摩擦学系统的实际意义将通过形成具有增加的粘附趋势的附加金属板材料来显示。在这种情况下，需要调整摩擦学系统以确保基体和抗体的分离，并在形成过程中减少和调整摩擦。在不同的研究所内，将实现以下步骤：1）考虑到另一种金属板材，在理解摩擦学系统方面取得进展。2)当前摩擦学系统的优化。3)用局部适应的摩擦学系统研究和扩展成形工艺的耐久运行过程稳定性。

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.