Investigation of Influencing Parameters for Tribological Conditions in Dry Forming Processes

Environmental awareness and a growing demand for efficient resource utilization encourage the realization of lubricant-free forming processes. A first step in accomplishing dry sheet metal forming is to gain knowledge about the changing tribological conditions and to identify the relevant influencing parameters. The commonly used flat strip drawing test was selected to investigate the tribological conditions in the flange area of deep drawing processes. The influencing factors of contact pressure and varying drawing velocities were analyzed under dry and lubricated conditions. Additionally, the tool and workpiece surfaces were characterized. Besides lubrication, the contact pressure mainly determines the tribological conditions. In lubricated tests higher normal pressure reduces friction, whereas without lubrication higher pressure results in slightly increasing friction. A changing drawing velocity affects the friction when lubricant is applied. In dry experiments, no influence of velocity was found. Results of surface characterization reveal adhesion as main wear mechanism under dry conditions. Based on the investigated influence of the process parameters, an increase in process understanding for dry forming operations is derived.