In-situ surface analysis for surface engineering in metal forming of lightweight alloys

轻质合金金属成形表面工程的原位表面分析

• 批准号: RGPIN-2015-06660
• 负责人: Riahi, Reza
• 金额: $ 1.82万
• 依托单位: University of Windsor
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2016
• 资助国家: 加拿大
• 起止时间: 2016-01-01 至 2017-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=614283
• 关键词: situ; surface; analysis; engineering; metal

The drive towards the application of lightweight materials such as aluminum and magnesium in various industries has led to the need for understanding the tribological interactions that occur during metal forming processes. In fact data from an industrial survey state two of the critical factors influencing metal forming processing are tribology of sheet metal forming and the design of dies. This is because the forming of lightweight metals is hindered by adhesion between these metals and the forming die/tool, which can lead to the reduction of the surface quality of the final product as well as tool life. Current die surface treatments and lubricants are unable to completely prevent this metal/die reaction. Therefore, a better understanding of the tribological interactions that occur between the die and metal is essential. This research seeks to mitigate the interactions by utilizing a multi-aspect tribological approach. The approach will consist of an experimental set-up designed to monitor, analyse and systematically characterise the mechanisms occurring during lubricated sliding contact between the die and workpiece surfaces. The set-up which will incorporate a high depth-of-focus microscope and a micro-Raman spectrometer for direct observation and 3D characterization of metal and die interactions. It will also be equipped with laser triangle sensors for the in-situ measurement and characterisation of the lubricant film which will determine the mechanisms influencing lubrication and COF due to die surface texturing and superposition of ultrasonic waves. Therefore, this experimental set-up will help to establish a novel in-situ technique for the determination and monitoring of lubrication conditions i.e. lubricant thickness and breakdown. The experimental results will also be applied to a plane strain compression set-up equipped with laser triangle sensors and ultrasonic wave transducer/generator system which simulates surface interactions in metal forming processes. The results will confirm the effect of surface texture and ultrasonic waves on deformation characteristics and surface quality especially at varying strains and strain rates at which metal forming occurs. In summary, this research project will establish an in-situ technique for monitoring lubrication film thickness and testing surface textures and ultrasonic waves effects used for friction control that will contribute to the production of surface defect free products in the Canadian metal forming industry. The forming industry will save millions of dollars that are invested to rectify surface defects on lightweight materials induced during metal forming and, therefore, increase their efficiency.

在各种行业中应用轻质材料（例如铝和镁）的推动力，导致需要理解金属形成过程中发生的摩擦学相互作用。实际上，来自工业调查状态的数据两个影响金属形成处理的关键因素是金属形成的摩擦学和模具设计。这是因为这些金属与形成模具/工具之间的附着力阻碍了轻质金属的形成，这可能导致最终产品的表面质量以及工具寿命的降低。当前的表面处理和润滑剂无法完全防止这种金属/模具反应。因此，对模具与金属之间发生的摩擦学相互作用的更好理解至关重要。这项研究试图通过利用多方面的摩擦学方法来减轻相互作用。该方法将包括一个实验设置，旨在监测，分析和系统地表征在模具和工件表面之间润滑滑动接触期间发生的机制。该设置将融合高焦点显微镜和微拉曼光谱仪，用于直接观察金属和模具相互作用。它还将配备激光三角传感器，用于对润滑剂膜的原位测量和表征，这将确定影响润滑和COF的机制，这是由于超声波的模具表面纹理和叠加而引起的。因此，这种实验设置将有助于建立一种新型的原位技术，以确定和监测润滑条件，即润滑厚度和分解。实验结果还将应用于配备激光三角传感器和超声波传感器/发电机系统的平面应变压缩设置，该设置模拟了金属形成过程中的表面相互作用。结果将证实表面纹理和超声波对变形特性和表面质量的影响，尤其是在发生金属形成的不同应变和应变速率下。总而言之，该研究项目将建立一种原位技术，用于监测用于摩擦控制的润滑膜厚度和测试表面纹理和超声波效应，这将有助于加拿大金属形成行业的无表面缺陷产品的生产。成立行业将节省数百万美元，这些美元用于纠正金属形成过程中引起的轻质材料的表面缺陷，从而提高其效率。