Investigation of the interactions of incremental surface layer forming and HPPMS coating on fine blanking dies in order to enable a load-applied surface integrity adjustment (TEStOI)

研究精冲模具上增量表面层成形和 HPPMS 涂层的相互作用，以实现负载施加的表面完整性调整 (TEStOI)

• 批准号: 423492562
• 负责人: Professor Dr.-Ing. Thomas Bergs
• 金额: --
• 依托单位: Werkzeugmaschinenlabor - WZL
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/423492562?language=en
• 关键词: Investigation; interactions; incremental; surface; layer

In the processing of high-strength sheet metal materials for the production of functional components such as brake pad carriers in the automotive industry by means of fine blanking the tool load increases compared to conventional sheet metal materials. Incremental methods for the mechanical surface layer forming, such as deep rolling, are suitable for increasing the tool lifetime by increasing the wear resistance. Mechanical surface treatment is used to improve the surface integrity (OI) of dynamically loaded parts. The OI includes microstructure, hardness profile, residual stresses, surface topography and damage of the tool surface layer. In order to further reduce abrasive and adhesive wear, the functional surfaces of the tools are coated by means of physical vapour deposition (PVD). Using a knowledge-based process design, it is possible to influence the OI of the coating selectively. A specific OI of the coating furthermore has a positive effect on the OI of the tool surface layer and the compound adhesion. In particular, the residual stress and the microstructure of the tool surface layer, however, can be successively relaxed by the thermal stress during the coating deposition as well as under cyclic elasto-mechanical stress of the surface layer during the fine blanking process. The corresponding physical cause-effect relationships with regard to the thermal and elastic stability of the OI are mostly unknown. On the one hand, it is unclear how the heat input during the coating process alters the OI of the tool and what interactions occur between the OI of the coating and the incrementally set OI in the tool. On the other hand, it is unknown how the cyclic elasto-mechanical load during the blanking process affects the OI of the tool surface layer. Therefore, the project is based on the research hypothesis that the OI which has been set by means of incremental surface layer transformation and PVD coating can be designed to be stable in a low-temperature coating process at substrate temperatures T < 300 °C under a friction-induced thermal and subsequent cyclic mechanical load. The thermal and elastic stability of the OI of the tool surface layer as well as the influence of the OI of the PVD coatings are investigated. On the one hand, the OI of the tool surface layer is specifically adjusted and then the tool surface is coated by means of a high-performance plasma process. On the other hand, investigations of the tool surface layer and coatings are carried out in order to analyze the influences of the production processes and to derive a suitable combination of process parameters. In order to expand the findings, the behaviour of the OI is examined in a numerical simulation.

在通过精冲加工用于生产汽车行业刹车片支架等功能部件的高强度钣金材料时，与机械表面层成型的传统钣金材料增量方法相比，刀具负载会增加。例如深滚压，适合通过提高耐磨性来延长刀具寿命。机械表面处理用于改善动态负载零件的表面完整性 (OI)。OI 包括微观结构、硬度分布、残余应力、表面形貌和表面形貌。的损坏为了进一步减少磨料和粘着磨损，通过物理气相沉积 (PVD) 方法对工具的功能表面进行涂层，可以影响涂层的 OI。此外，涂层的特定 OI 对工具表面层的 OI 和化合物粘附力具有积极影响，特别是，工具表面层的残余应力和微观结构可以通过热连续松弛。期间的压力一方面，精冲过程中涂层沉积以及表面层的循环弹性机械应力与 OI 的热稳定性和弹性稳定性的相应物理因果关系大多是未知的。目前尚不清楚涂层过程中的热输入如何改变工具的 OI，以及涂层的 OI 与工具中逐渐凝固的 OI 之间会发生什么相互作用。另一方面，尚不清楚循环弹性机械如何发生。冲裁过程中的负载会影响刀具表面层的OI，因此，该项目基于这样的研究假设：通过增量表面层转变和PVD涂层设置的OI可以设计成稳定在较低水平。 -在摩擦引起的热和随后的循环机械负载下，基材温度 T < 300 °C 的温度涂层过程工具表面层 OI 的热稳定性和弹性稳定性以及 PVD ​​涂层 OI 的影响。调查了。一方面，对刀具表层的OI进行专门调整，然后通过高性能等离子工艺对刀具表面进行涂层处理；另一方面，对刀具表层和涂层进行有序的研究。分析生产工艺的影响并得出合适的工艺参数组合 为了扩展研究结果，我们通过数值模拟检查了 OI 的行为。