Roles of Process Parameters and Materials Properties on Galling During Blanking and Punching of Aluminum Sheets

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The collaborative NSERC Engage research project undertaken by the University of Windsor and Novelisresearchers resulted in providing an new and efficient method for measuring the amount of aluminumtransferred to the tool surfaces during shearing and punching of aluminum sheets. The use of this methodbased on white light interferometry will allow to determine Al galling rate as a function of processparameters, such as clearance percentage, angle, pressure and using different lubrication strategies.Furthermore a correlation was established between the cut edge features (burnish and shear fracture) and thegalling volume increase with the number of press cycles. The NSERC Engage Plus program is intended tobuild on these achievements improve our understanding of Al galling problem.The objectives of the proposed research include i) studying the effect of variation in clearance and lubricant onAl galling and trimmed edge features; ii) investigation of the influence of mechanical properties of thealuminum sheets on the trimmed edge quality; iii) use of carbon based tool coatings in conjunction with theappropriate selection of lubricants which to mitigate galling improve the tool life as well as the sheared edgequality.