Process-Integrated Lubrication in Sheet Metal Forming

authored by: Roland Lachmayer, Bernd Arno Behrens, Tobias Ehlers, Philipp Müller, Philipp Althaus, Marcus Oel, Ehsan Farahmand, Paul Christoph Gembarski, Hendrik Wester, Sven Hübner
Abstract: The deep-drawability of a sheet metal blank is strongly influenced by the tribological conditions prevailing in a deep-drawing process. Therefore, new methods to influence the tribology represent an important research topic. In this work, the application of a process-integrated lubrication in a deep-drawing process is investigated. Most promising geometries of the lubrication channels and outlet openings are first identified by means of numerical simulation at the example of a demonstrator process. Cylindrical test specimens with the specified channel geometries are additively manufactured and installed in a strip drawing test stand. Additive manufacturing enables the possibility of manufacturing complex channel geometries which cannot be manufactured by conventional methods. A hydraulic metering device for conveying lubricant is connected to the cylindrical test specimens. Thus, hydraulically lubricated strip drawing tests are performed. The tests are evaluated according to the force curves and the fluid mechanical buildup of pressure cushion. The performance of process-integrated lubrication is thus analyzed and evaluated. By means of a coupled forming and SPH simulation, the lubrication channels could be optimally designed. From the practical tests, it could be achieved that the drawing force decreases up to 27% with pressure cushion build up. In this research, a hydraulic lubrication in the area of highest contact normal stresses is the most optimal process parameter regarding friction reduction.
Organisation(s): Institute of Motion Engineering and Mechanism Design
Institute of Metal Forming and Metal Forming Machines
Type: Article
Journal: Journal of Manufacturing and Materials Processing
Volume: 6
No. of pages: 24
Publication date: 10.2022
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanics of Materials, Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.3390/jmmp6050121 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{8cd4a1a0a48748bd9987124745476f42,
title = "Process-Integrated Lubrication in Sheet Metal Forming",
abstract = "The deep-drawability of a sheet metal blank is strongly influenced by the tribological conditions prevailing in a deep-drawing process. Therefore, new methods to influence the tribology represent an important research topic. In this work, the application of a process-integrated lubrication in a deep-drawing process is investigated. Most promising geometries of the lubrication channels and outlet openings are first identified by means of numerical simulation at the example of a demonstrator process. Cylindrical test specimens with the specified channel geometries are additively manufactured and installed in a strip drawing test stand. Additive manufacturing enables the possibility of manufacturing complex channel geometries which cannot be manufactured by conventional methods. A hydraulic metering device for conveying lubricant is connected to the cylindrical test specimens. Thus, hydraulically lubricated strip drawing tests are performed. The tests are evaluated according to the force curves and the fluid mechanical buildup of pressure cushion. The performance of process-integrated lubrication is thus analyzed and evaluated. By means of a coupled forming and SPH simulation, the lubrication channels could be optimally designed. From the practical tests, it could be achieved that the drawing force decreases up to 27% with pressure cushion build up. In this research, a hydraulic lubrication in the area of highest contact normal stresses is the most optimal process parameter regarding friction reduction.",
keywords = "additive manufacturing (AM), deep-drawing, design for additive manufacturing (DfAM), functional integration, laser powder bed fusion (LPBF), lubrication",
author = "Roland Lachmayer and Behrens, {Bernd Arno} and Tobias Ehlers and Philipp M{\"u}ller and Philipp Althaus and Marcus Oel and Ehsan Farahmand and Gembarski, {Paul Christoph} and Hendrik Wester and Sven H{\"u}bner",
note = "Funding Information: This research was funded by the IGF—Industrielle Gemeinschaftsforschung, grant number 21586N and “The APC was funded by the IGF—Industrielle Gemeinschaftsforschung”. ",
year = "2022",
month = oct,
doi = "10.3390/jmmp6050121",
language = "English",
volume = "6",
journal = "Journal of Manufacturing and Materials Processing",
issn = "2504-4494",
publisher = "MDPI Multidisciplinary Digital Publishing Institute",
number = "5",
}