Ultra-fine Surface Production by Plastic Deformation

对工业纯铝带形工件进行压平试验，试验中冲头的表面粗糙度不同，润滑条件和减薄量也有很大差异，试验结果表明，减薄可以获得超精细的表面。在模具侧，使用低粘度润滑油时，经常会产生磨损。当使用较高粘度的油时，金属表面成为摩擦表面（Ra=0.05 μ m），这在本实验中是最好的，但不如模具表面。在冲头侧，金属表面成为冲头表面的近复制品，并且复制度可以用较大的减少量和较低粘度的油或干燥时升高。当应用冲头Ra=0.02 μ m时，如果减小量上升到20%，则金属表面变成冲头的完全复制品。在采用Ra= 0.004 μ m的SKD11边缘表面光洁度的凸模，在干拉深条件下，Re= 50%时，也能得到完整的凸模复制品。因此，在变薄拉深过程中，可以利用复型机构对靠近凸模表面的金属表面进行精加工。

Flattening tests on band workpieces of commercially pure aluminum with punches of differing surface roughnesses and widely different lubricating conditions as well as ironing reductions have shown that an extra-fine surface can be obtained by the ironing process.On the die side, galling often occurs when low viscosity oils are used. When higher viscosity oils are employed, the metal surface becomes a rubbed surface (Ra=0.05 mum) which is the best in this experiment but rather inferior to the die surface.On the punch side, the metal surface becomes a near-replica of the punch surface, and the replica degree can be elevated with larger reductions and lower viscosity oils or when dry. When applying the punch Ra=0.02 mum, if the reduction rises to 20%, the metal surface becomes a complete replica of the punch. And in the case of applying the punch Ra=0.004mum,which is marginal surface finish of SKD11, under ironing conditions of dry and Re=50%, a complete replica of the punch can also be obtained. In conclusion, the metal surface near the punch surface can be finished by a replica mechanism in the ironing process.