Control of the material flow in sheet-bulk metal forming using modifications of the tool surface

Sheet-bulk metal forming (SBMF) processes are characterized by a successive and/or simultaneous occurrence of different load conditions such as the stress and strain states. These conditions influence the material flow and often lead to a reduced geometrical accuracy of the produced components. To improve the product quality, a control of the material flow is required. One suitable approach, the local adaption of tribological conditions by means of surface modifications of tool or workpiece, so-called tailored surfaces. To control the material flow and thus to improve the component accuracy, methods to reduce and to increase friction are needed. The aim of this study is to determine requirements for necessary adaptions of the friction, the identification of tribological mechanisms for different types of tool-sided tailored surfaces as well as the verification of the effectiveness of these surface modifications to improve the results of a specific SBMF process. The numerical analysis of a combined deep drawing and upsetting process revealed that this process is characterized by two areas of varying tribological load conditions. Using a numerical analysis, the friction factor gradient between these two areas was identified as a main influencing factor on the material flow. Based on this finding, Chromium-based hard coatings for the reduction of the friction and high-feed milled surfaces for an increase of the friction were investigated regarding their frictional behaviour. The results of the ring-compression tests revealed that the carbon content and the post treatment of coated tool surfaces are relevant to reduce the friction. The increased profile depth of the milled surfaces was identified as the main influencing factor on the tribological behaviour of this kind of tailored surfaces. The effectiveness of both types of tailored surfaces was verified for the combined deep drawing and upsetting process.