Lubricants are necessary to avoid adhesion, galling, and scratching in aluminum stamping processes. In this study, various lubricants, including dry lubes and wet lubes, were evaluated using cup drawing test (CDT) for stamping of Al 5182-O aluminum sheets. The effects of surface texturing, with electro-discharge texturing (EDT) and mill finish (MF), on the friction behavior were also investigated. Furthermore, the methodology to evaluate the performance of lubricants was established based on (a) maximum applicable blank holder force (BHF) and (b) draw-in length in flange or flange perimeter of formed cups. Finite element (FE) simulations were carried out to determine the coefficient of friction (CoF) at tool–workpiece interface during deep drawing under different lubrication conditions. Flow stress data of Al 5182-O material were obtained using viscous pressure bulge (VPB) and tensile tests. In this study, it was confirmed that, in forming Al 5182-O, dry film lubricants have better lubricity than wet lubricants. A better lubrication condition was found with EDT surface texture.

References

1.
Groche
,
P.
,
Nitzsche
,
G.
, and
Elsen
,
A.
,
2008
, “
Adhesive Wear in Deep Drawing of Aluminum Sheets
,”
CIRP Ann. Manuf. Technol.
,
57
(
1
), pp.
295
298
.10.1016/j.cirp.2008.03.042
2.
Meiler
,
M.
,
Pfestorf
,
M.
,
Merklein
,
M.
, and
Geiger
,
M.
,
2004
, “
Tribological Properties of Dry Film Lubricants in Aluminum Sheet Metal Forming
,” 2nd ICTMP, Nyborg, Denmark, June 15–18, pp.
489
500
.
3.
Meiler
,
M.
, and
Jaschke
,
H.
,
2005
, “
Lubrication of Aluminum Sheet Metal Within the Automotive Industry
,”
Adv. Mater. Res.
,
6-8
, pp.
551
558
.10.4028/www.scientific.net/AMR.6-8.551
4.
Wei
,
J.
,
Erdemir
,
A.
, and
Fenske
,
G. R.
,
2000
, “
Dry Lubricant Films for Aluminum Forming
,”
Tribol. Trans.
,
43
(
3
), pp.
535
541
.10.1080/10402000008982374
5.
Meiler
,
M.
,
Pfestorf
,
M.
,
Geiger
,
M.
, and
Merklein
,
M.
,
2003
, “
The Use of Dry Film Lubricants in Aluminum Sheet Metal Forming
,”
Wear
,
255
(
7
), pp.
1455
1462
.10.1016/S0043-1648(03)00087-5
6.
Kim
,
H.
,
Sung
,
J.
,
Goodwin
,
F. E.
, and
Altan
,
T.
,
2008
, “
Investigation of Galling in Forming Galvanized Advanced High Strength Steels (AHSSs) Using the Twist Compression Test (TCT)
,”
ASME J. Mater. Process. Technol.
,
205
(
1
), pp.
459
468
.10.1016/j.jmatprotec.2007.11.281
7.
Kim
,
H.
,
Sung
,
H.
,
Sivakumar
,
R.
, and
Altan
,
T.
,
2007
, “
Evaluation of Stamping Lubricants Using the Deep Drawing Test
,”
Int. J. Mach. Tools Manuf.
,
47
(
14
), pp.
2120
2132
.10.1016/j.ijmachtools.2007.04.014
8.
Subramonian
,
S.
,
Kardes
,
N.
,
Demiralp
,
Y.
,
Jurich
,
M.
, and
Altan
,
T.
,
2011
, “
Evaluation of Stamping Lubricants in Forming Galvannealed Steels for Industrial Application
,”
ASME J. Manuf. Sci. Eng.
,
133
(
6
), p.
061016
.10.1115/1.4003948
9.
Liewald
,
M.
,
Wagner
,
S.
, and
Becker
,
D.
,
2010
, “
Influence of Surface Topography on the Tribological Behaviour of Aluminium Alloy 5182 With EDT Surface
,”
Tribol. Lett.
,
39
(
2
), pp.
135
142
.10.1007/s11249-010-9625-1
10.
Hartfield-Wunsch
,
S.
,
Cohen
,
D.
,
Sanchez
,
L.
, and
Brattstrom
,
L.
,
2011
, “
The Effect of Surface Finish on Aluminum Sheet Friction Behavior
,” SAE Technical Paper No. 2011-01-0534.
11.
Raharijaona
,
F.
,
Roizard
,
X.
, and
Stebut
,
J. V.
,
1999
, “
Usage of 3D Roughness Parameters Adapted to the Experimental Simulation of Sheet–Tool Contact During a Drawing Operation
,”
Tribol. Int.
32
(
1
), pp.
59
67
.10.1016/S0301-679X(99)00019-5
12.
Zhou
,
R.
,
Cao
,
J.
,
Wang
,
Q. J.
,
Meng
,
F.
,
Zimowski
,
K.
, and
Xia
,
Z. C.
,
2011
, “
Effect of EDT Surface Texturing on Tribological Behavior of Aluminum Sheet
,”
J. Mater. Process. Technol.
,
211
(
10
), pp.
1643
1649
.10.1016/j.jmatprotec.2011.05.004
13.
Groche
,
P.
, and
Möller
,
N.
,
2012
, “
Tribological Investigation of Deep-Drawing Processes Using Servo Presses
,”
ASME
Paper No. MSEC2012-7292, pp.
127
137
.10.1115/MSEC2012-7292
14.
Nasser
,
A.
,
Yadav
,
A.
,
Pathak
,
P.
, and
Altan
,
T.
,
2010
, “
Determination of the Flow Stress of Five AHSS Sheet Materials (DP 600, DP 780, DP 780-CR, DP 780-HY and TRIP 780) Using the Uniaxial Tensile and the Biaxial Viscous Pressure Bulge (VPB) Tests
,”
J. Mater. Process. Technol.
,
210
(
3
), pp.
429
436
.10.1016/j.jmatprotec.2009.10.003
15.
Brem
,
J. C.
,
Barlat
,
F.
,
Dick
,
R. E.
, and
Yoon
,
J. W.
,
2005
, “
Characterizations of Aluminum Alloy Sheet Materials Numisheet 2005
,” AIP Conf. Proc., Detroit, MI, Aug. 15–19.
16.
Leu
,
D. K.
, and
Sheen
,
S. H.
,
2013
, “
Roughening of Free Surface During Sheet Metal Forming
,”
ASME J. Manuf. Sci. Eng.
,
135
(
2
), p.
024502
.10.1115/1.4023713
You do not currently have access to this content.