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

大多数金属成形过程使用以矿物油为基础的润滑剂作为减少摩擦和磨损的中间介质。然而，这些润滑剂可能含有有毒的添加剂，成形的零件需要为进一步的工艺步骤进行清洗，这非常耗时和膨胀。在前两个供资期间，为金属成形过程引入了一种创新的、环境友好的润滑系统。液态二氧化碳和气态氮气被用作挥发性润滑剂。这种新的摩擦学系统适用于干金属成形过程，并通过单一成形工艺进行了验证。第三个资助期的目标是展示这一新的摩擦学系统在干法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力运行中形成过程的适用性。对于本演示，有必要确保过程稳定性。为了提高工艺的稳定性，必须对新的摩擦学系统进行优化。深入了解这一复杂的摩擦学系统中的摩擦磨损机理是优化的基础。此外，重要的是要了解成型过程中挥发性润滑剂介质逸出的物理机制。为了确保工艺的稳定性，必须进行高精度和高质量的微钻加工。没有任何毛刺的精确钻孔保证了挥发性润滑油介质的稳定和可重复流动，并避免了任何额外的摩擦。表面结构的产生确保了挥发性洗脱介质的均匀分布，这是朝着提高工艺稳定性迈出的又一步。这种新的摩擦学系统的实际意义将通过形成更多的具有更强粘附性的金属板材来展示。在这种情况下，摩擦学系统需要调整，以确保基本体和抗体的分离，并减少和适应形成过程中的摩擦。在不同的研究所内，将实现以下步骤：1)在考虑到另一种金属板材的情况下，提高对摩擦学系统的理解。2)优化现有的摩擦学系统。3)用局部适应的摩擦学系统研究和扩展成形过程中的工艺稳定性。

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.