Lubricant free forming with tailored tribological conditions

在定制的摩擦条件下进行无润滑成型

• 批准号: 282248914
• 负责人: Professorin Dr.-Ing. Marion Merklein
• 金额: --
• 依托单位: Lehrstuhl für Photonische Technologien (LPT)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2015
• 资助国家: 德国
• 起止时间: 2014-12-31 至 2020-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/282248914?language=en
• 关键词: Lubricant; free; forming; tailored; tribological

The results of the first and the second project phase show that the direct contact during dry deep drawing leads to intensive interactions between tool and sheet surface. With conventional tools, lubricant-free deep drawing causes increasing forming forces, local wear occurrence and failure in form of cracks depending on the sheet material. This motivates the development of surface modifications which reduce friction as well as wear and thus, help to control the material flow. As approach in the first and second project phases, amorphous carbon based coatings and laser based surface modifications have been developed and analyzed regarding their tribological behavior. Reduction of friction and wear is achieved by ta-C and a-C:H coatings while a laser based heat treatment and microstructuring are applied to control the material flow in the deep drawing process. Promising surface modifications have been applied on blank holder and die in order to realize a dry deep drawing of rectangular cups. Under dry conditions, the application of ta-C coatings leads to a reduced forming force and increased surface quality of the cups for steel and aluminum alloys in comparison to cups drawn with uncoated tools. This demonstrates the feasibility of dry deep drawing with the help of the measures chosen in this research project. However, it is not clear how the tribological behavior of the developed modifications changes at long sliding distances. Thus, the main objective of the third project phase is the investigation of run-in and wear behavior of the surface modifications under varied load conditions. This knowledge will be used in order to increase the wear resistance. Regarding the coating process, coating designs and deposition parameters will be adapted to improve the wear behavior of the coatings. In addition, laser based measures in terms of heat treatment, microstructuring and smoothing will be developed and analyzed. A heat treatment of coated surfaces could reduce critical residual stresses while microstructures are able to collect wear particles and keep them away from the contact zone. Challenging sheet properties which are associated with increasing contact and shear stresses will be investigated as well. This will prove whether the selected measures enable dry deep drawing for a broad range of applications.

第一个项目和第二个项目阶段的结果表明，在干深图中的直接接触导致工具和薄板表面之间的密集相互作用。借助常规工具，无润滑剂的深度绘图会导致增加形成力，局部磨损的发生以及裂缝形式的失败，具体取决于板材的材料。这激发了表面修饰的发展，从而减少摩擦和磨损，从而有助于控制材料流。作为第一个和第二个项目阶段的方法，已经开发了并分析了基于无定形的碳涂层和基于激光的表面修饰其摩擦学行为。通过TA-C和A-C：H涂层实现摩擦和磨损的减少，同时采用基于激光的热处理和微结构来控制深度绘图过程中的材料流。为了实现矩形杯子的干深图纸，已对空白支架进行了有希望的表面修饰。在干燥条件下，与使用未涂层工具一起绘制的杯子相比，使用TA-C涂层会导致钢和铝合金的杯子表面质量降低，并提高了钢和铝合金的杯子表面质量。这证明了借助此研究项目所选择的措施，干深绘图的可行性。但是，尚不清楚开发修饰的摩擦学行为如何在长滑动距离下变化。因此，第三个项目阶段的主要目的是研究各种负载条件下表面修饰的磨损和磨损行为。这些知识将用于增加耐磨性。关于涂料工艺，将适应涂料设计和沉积参数，以改善涂料的磨损行为。此外，将开发和分析基于激光的措施，微结构和平滑。对涂层表面的热处理可以减少临界残留应力，而微观结构能够收集磨损颗粒并使它们远离接触区。还将研究与接触增加和剪切应力相关的具有挑战性的表格性能。这将证明所选措施是否可以为广泛的应用提供干燥的深度图。