Tribological Technology in Sheet Metal Forming (Materials Forming, Machining and Tribology)

This state-of-the-art book highlights recent advances and discussions in tribological technologies in sheet metal forming. The contents focus on the fundamentals to the more complex topics such as micro contact and lubricant behaviors, FEM analysis in deep drawing process, usage of tribo-simulators, friction behavior in flat sliding, tribological numerical modeling, and simulation of seizure. This book is a useful reference for academicians and researchers in the field of lubrication, sheet metal forming, and tooling. Preface Contents 1 Direct Observation of Lubrication Behavior 1.1 Direct Observation in Drawing Between Flat Dies 1.1.1 Apparatus for Direct Observation and Experiments 1.1.2 Effect of Average Pressure on Coefficeint of Friction 1.1.3 Friction Model in Lower Average Contact Pressure 1.1.4 Effect of Surface Topography of Workpiece 1.2 Direct Observation in Sheet Drawing 1.2.1 Apparatus for Direct Observation 1.2.2 Micro-plasto-Hydrodynamic Lubrication 1.3 In Lubro 3D Measurement of Oil Film Thickness at Interface 1.3.1 In Lubro Fluorescence Microscopy 1.3.2 In Lubro Measurement of Oil Film Thickness in Drawing Between Flat Dies 1.3.3 In Lubro Measurement of Oil Film Thickness in Sheet Drawing References 2 Friction Behavior in Drawing Between Flat Dies 2.1 New Tribo-simulator Controlled by Computer 2.1.1 New Tribo-simulator 2.1.2 Experimental and Results 2.2 Effect of Lubricant Viscosity and Additive on Coefficient of Friction 2.2.1 Experimental 2.2.2 Results and Discussion 2.3 Effect of Yield Stress on Coefficient of Friction 2.3.1 Experimental 2.3.2 Results and Discussion 2.4 Effect of Bulk Deformation of Specimen on Coefficient of Friction 2.4.1 New Testing Method for Elongation Control of Specimen 2.4.2 Experimental 2.4.3 Results and Discussion 2.5 Effect of Back Tension on Coefficient of Friction 2.5.1 New Testing Method for Back Tension Control and Experimental 2.5.2 Results and Discussion References 3 Friction Behavior in Flat Sliding 3.1 Apparatus and Characteristic of Flat Sliding 3.2 Effect of Surface Topography on Coefficient of Friction of Steel Sheet 3.2.1 Experimental 3.2.2 Results 3.2.3 Discussion 3.3 Effect of Contact Length of Die on Coefficient of Friction of Steel Sheet 3.3.1 Experimental 3.3.2 Results 3.3.3 Discussion 3.4 Friction Behavior in Flat Sliding of Plated Steel Sheet 3.4.1 Experimental 3.4.2 Results and Discussion 3.5 Friction Behavior in Flat Sliding of Aluminum Alloy Sheet 3.5.1 Experimental 3.5.2 Results and Discussion References 4 Friction Behavior in Repeatedly Flat Sliding 4.1 Apparatus and Characteristics 4.2 Effect of Yield Stress on Coefficient of Friction 4.2.1 Experimental 4.2.2 Results 4.2.3 Discussion 4.3 Friction Behavior of Flat Sliding of Plated Steel Sheet 4.3.1 Experimental 4.3.2 Results and Discussion References 5 Friction Behavior in Tension-Bending 5.1 Surface Behavior of Specimen with Dull Surface in Sliding Under Tension-Bending 5.1.1 Apparatus 5.1.2 Experimental 5.1.3 Results and Discussion 5.2 Surface Behavior of Specimen with Smooth Surface in Sliding Under Tension-Bending 5.2.1 Experimental 5.2.2 Results and Discussion 5.3 Direct Observation of Micro-contact Behavior at Interface in Sliding Under Tension-Bending 5.3.1 Apparatus 5.3.2 Experimental 5.3.3 Results and Discussion 5.4 Coefficient of Friction by Tribo-simulator Controlled by Computer 5.4.1 Apparatus 5.4.2 Experimental 5.4.3 Results and Discussion References 6 Friction Behavior in Ironing 6.1 Coefficient of Friction by Fundamental Tribo-simulators 6.1.1 Experimental 6.1.2 Results 6.1.3 Effect of Chemical Composition on Coefficient of Friction by SRV Test 6.2 Coefficient of Friction of Commercial Oils by New Tribo-simulator 6.2.1 New Tribo-simulator 6.2.2 Coefficient of Friction of Commercial Oils by New Tribo-simulator 6.2.3 Coefficient of Friction of Surface Coated Die by New Tribo-simulator References 7 FEM Analysis of Friction Behavior in Deep Drawing 7.1 Measurement of Punch Load in Deep Drawing 7.1.1 Experimental 7.1.2 Results and Discussion 7.2 FEM Analysis of Punch Load in Cylindrical Cup Deep Drawing 7.2.1 Analytical Method 7.2.2 Results and Discussion 7.3 Effect of Friction Behavior on Formability in Deep Drawing 7.3.1 Measurement of Formability in Semi-spherical Cup Deep Drawing 7.3.2 FEM Analysis of Formability in Semi-spherical Cup Deep Drawing 7.3.3 FEM Analysis of Fracture in Semi-spherical Cup Deep Drawing References 8 Tribological Numerical Modeling in Sheet Drawing 8.1 Coefficient of Friction 8.1.1 Method to Obtain Coefficient of Friction Using Tribo-simulator 8.1.2 Method to Obtain Coefficient of Friction Using Normal and Drawing Forces 8.1.3 Coefficient of Friction Calculated from Normal and Drawing Forces Measured 8.2 New Coefficient of Friction 8.3 Tribological Numerical Modeling for Coefficient of Friction in Sheet Drawing 8.3.1 Lubrication Models 8.3.2 Mixed Lubrication of Hydrodynamic Lubrication, Hydrostatic Lubrication and Boundary Lubrication 8.4 Inlet Oil Film Thickness 8.5 Tribological Numerical Modeling in Sheet Drawing 8.5.1 Formulation of Area Ratio of Boundary Lubrication Region 8.5.2 Coefficient of Friction in Tribological Numerical Modeling 8.6 Numerical Calculation of Coefficient of Friction 8.6.1 Calculation Conditions 8.6.2 Calculation Results and Discussion 8.7 Remarks References 9 Simulation of Seizure in Sheet Metal Forming 9.1 Simulation of Seizure in Flat Sliding Test 9.1.1 Introduction of Some Data in Chap. 3 9.1.2 Experimental 9.1.3 Results and Discussion 9.1.4 Remarks 9.2 Simulation of Seizure in Repeatedly Flat Sliding Test 9.2.1 Introduction to Some Data in Chap. 4 9.2.2 Effect of Yield Stress on Seizure by Repeatedly Flat Sliding 9.3 Simulation of Seizure in Ironing 9.3.1 New Tribo-simulator 9.3.2 Evaluation of Commercial Oils for Ironing by New Tribo-simulator 9.3.3 Evaluation of Commercial Lubricants for Ironing Using Surface Coated Die by New Tribo-simulator 9.3.4 Evaluation of Non-chlorine Lubricant with High Lubricity for Ironing by New Tribo-simulator 9.3.5 Development of Non-chlorine Lubricant with High Lubricity for Ironing by New Tribo-simulator References 10 Lubrication in Hot Stamping 10.1 Development of Tribo-simulator for Lubrication in Hot Stamping 10.1.1 Test Machine 10.1.2 Property of Infrared Image Furnace 10.1.3 Measurement of Coefficient of Friction 10.2 Lubrication in Hot Stamping of Aluminum-Coated 22MnB5 Steel 10.2.1 Experimental 10.2.2 Results of Heating 10.2.3 Results of Coefficient of Friction Under Dry Condition 10.2.4 Results of Coefficient of Friction Under Lubricated Condition 10.2.5 Effect of Surface Coated Die on Coefficient of Friction Under Dry Conditions 10.2.6 Thermal Behavior Under Dry and Lubricated Conditions 10.2.7 Development of New Lubricant for Hot Stamping of Al-Coated 22MnB5 Steel 10.2.8 Adhesion Behavior of Aluminum on Die Surface 10.3 Lubrication in Hot Stamping of AA7075 Aluminum Alloy 10.3.1 Experimental 10.3.2 Effect of Composition of Lubricant on Coefficient of Friction 10.3.3 Effect of Viscosity of Synthetic Ester Oil on Coefficient of Friction 10.3.4 Effect of Normal Load on Coefficient of Friction 10.3.5 Effect of Extreme Pressure Additive on Coefficient of Friction 10.3.6 Effect of Solid Lubricant on Coefficient of Friction References Index