ERC NSM R&D Update on Friction & Lubrication for Metal Forming Engineering Research Center for Net Shape Manufacturing The Ohio State University Columbus, Ohio www.ercnsm.org April 2005 © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Outline ERC NSM Objectives – Industrially Relevant Friction & Lubrication Research Tests to Evaluate Lubricants for Forging - Double Cup Extrusion Test for cold forging - Ring Compression Test for cold & hot forging Tests to Evaluate Lubricants for Stamping / Hydroforming - Ironing Test - Modified Limit Dome Height Test - The Guiding Zone / Expansion Zone Tests © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Objectives – Industrially Relevant Friction & Lubrication Research ERC NSM • Reliable evaluation of lubricants used in various metal forming processes (stamping, forging and hydroforming) • Development of effective lubricants for emerging novel manufacturing processes such as: - Sheet hydroforming - Microforming - Warm Forming of Tube and Sheet • Replacement of phosphate and graphite based lubricants with environmental friendly lubricants © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Tests to Evaluate Lubricants for Forging ERC NSM - Double Cup Extrusion Test The ratio of the cup heights, Rch, increases with increasing coefficient of friction (or friction factor, m) Rch = h1/h2 © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Tests to Evaluate Lubricants for Forging ERC NSM - Double Cup Extrusion Test h1 h2 Initial billet Formed billet • Ranking the lubricants based on cup height ratio (Rch = h1 / h2) • Surface analysis is done on the cut specimen to investigate galling • By comparing the experimental and FE results of cup height ratio (Rch) vs stroke curves, the friction factor (m) will be determined © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Tests to Evaluate Lubricants for Forging ERC NSM - Double Cup Extrusion Test List of Recently Published Reports and Papers • Report No ERC/NSM-05-R-13 entitled “A Cold Forming Coating / Lubricant Study (A Collaborative Study between Henkel Surface Technologies and The Ohio State University)” (2005) • Report No F/ERC/NSM-02-R-85 entitled “Development of Replacements for Phoscoating used in Forging, Extrusion and Metal Forming Processes” (2002) • Kim, H., Shriniwas, P and Altan, T "Evaluation of New Lubricants for Cold Forging Without Zinc Phosphate Coating", Proceedings of the International Cold Forging Group 37th Plenary Meeting, Istanbul, Turkey, Sep 13-15, 2004 (Paper No 525-1) • Gariety, M., Ngaile, G and Altan T "Evaluation of Environmentally Friendly Lubricants for Cold Forging Processes", submitted to the International Journal of Machine Tool and Manufacture, July 2003 (Paper No 525) © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Tests to Evaluate Lubricants for Forging ERC NSM - Ring Compression Test • Evaluation of lubricant performance (RT ~ 200 deg C) • Investigation of the effect of surface topography (i.e surface roughness or the real contact area ratio) on friction and lubrication • Investigation of friction in function of stroke and location Ri Ri - The reduction of inner diameter (Ri) indicates the friction on ring surface © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Tests to Evaluate Lubricants for Forging ERC NSM - Ring Compression Test Effect of Die temperature on Lubrication condition Test Conditions RC1 Final Ring Geometries ID: 19.78 mm (top), 20.56 mm (bottom) Lubricated (top & bottom) TD:150 °C BD, Ring: 25 °C Speed: 65mm/sec RC2 ID: 19.81 mm (top & bottom) Lubricated (top & bottom) TD,BD,Ring:150 °C Speed: 65mm/sec RC3 ID: 18.71 mm (top), 19.98 mm (bottom) Dry (top) Lubricated (bottom) TD,BD,Ring:150 °C Speed: 65mm/sec [ Note: TD = the top die, and BD = the bottom die, Initial ring dimensions: OD / ID / height = 35/18/18 mm, made from AISI 1018 HR steel ] © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Tests to Evaluate Lubricants for Forging ERC NSM - Ring Compression Test List of Recently Published Reports • Report No PF/ERC/NSM-05-R-14 entitled “Investigation of Friction in Metal Forming Using The Ring Compression Test (Phase I: Effects of Surface Topography on Friction)” (2005) • Report No PF/ERC/NSM-04-R-28 entitled “Investigation of the Effect of Temperature on Lubrication and Flow Stress in Cold Forming Using the Ring Compression Test” (2005) • Report No PF/ERC/NSM-04-R-21 entitled “Micro-Tribology for Metal forming – A Literature Review” (2004) © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved Tests to Evaluate Lubricants for Stamping / Hydroforming - Ironing Test ERC NSM Ironing Test developed at ERC/NSM successfully reproduces production conditions (contact pressure up to 650 MPa (= 94.2 ksi) and temperature up to 150 °C (=302 °F) in a laboratory setup Schematic of Ironing process The ironing test was used to determine the performance of dry-film lubricants under production conditions © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 10 ERC Tests to Evaluate Lubricants for Stamping / Hydroforming - Ironing Test NSM The performance of lubricants is evaluated based on the following evaluation criteria: The maximum ironing load attained Surface topography of the ironed cups after test Cup wall thinning Temperature range at which the lubricant fails Coating weight loss or lubricant build-up on die Lub B (RT) 16.00 Lub A (RT) Ironing Load [ton] 14.00 12.00 10.00 8.00 6.00 4.00 2.00 0.00 0.00 10.00 20.00 30.00 Stroke [m m] 40.00 50.00 Coating loss weight/unit area [g/m^2] • • • • • Initial coating weight per unit area: 6.5 g/m^2 Lub A Lub B © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 11 Tests to Evaluate Lubricants for Stamping / Hydroforming - Ironing Test ERC NSM List of Recently Published Reports and Papers • Report No ERC/NSM-05-R-06 entitled “Performance Evaluation of Dry Film Lubricants at Various Temperatures Using Ironing Tribotest” (2005) • Report No S/ERC/NSM-02-R-38 entitled “Performance Evaluation of Stamping Lubricants at Various Temperatures Using Ironing Test” (2002) • Report No S/ERC/NSM-02-R-37 entitled “Evaluation of Lubricants at Different Temperatures Using Deep Drawing and Ironing” (2002) • Chandrasekharan, S., Palaniswamy, H., Jain, N and Altan, T "Evaluation of Stamping Lubricants at Various Temperature Levels using the Ironing Test", The International Journal of Machine Tools & Manufacture, November 2003 (Paper No 539) • ERC/NSM "Evaluation of Stamping Lubricants using the Ironing Test", R&D Update, Stamping Journal, November/December, 2003, p.50 (Paper No 501-6) © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 12 ERC Tests to Evaluate Lubricants for Stamping / Hydroforming –Modified Limiting Dome Height TestNSM - Modified LDH test • A hole is drilled at the center of cold rolled AKDQ sheet specimen • The sheet is stretched over a hemispherical punch mm hole Note: The stroke was limited to 44 mm to avoid any fracture © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 13 ERC Tests to Evaluate Lubricants for Stamping / Hydroforming –Modified Limiting Dome Height TestNSM Lubricant A Lubricant B 15.40 mm 56 kN 16.59 mm 53 kN After punch stroke of 44 mm Measurements Hole diameter : Max load : Ỵ A larger hole expansion and lower max load = Better performance of the lubricant used © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 14 ERC Tests to Evaluate Lubricants for Stamping / Hydroforming –Modified Limiting Dome Height TestNSM List of Recently Published Reports and Papers • Report No S/ERC/NSM-02-R-57 entitled “MODIFIED LIMITING DOME HEIGHT TEST” (2002) • Report No S/ERC/NSM-01-R-14-THF entitled “Estimation of Friction Coefficients of Lubricants Used in TH/Comparison of Limiting Dome Height” (2001) • Report No S/ERC/NSM-00-R-13A-THF entitled “Determination of Friction Coefficient and Ranking of Lubricants for Tube Hydroforming (THF) by Limiting Dome Height (LDH) Test Progress Report I - The Case of Transition Zone in THF” (2000) •Ngaile, G., Jaeger, S., and Altan T "Lubrication in Tube Hydroforming-Part II., LDH Test and Pear Shaped Expansion Test" , Journal of Materials Processing Technology, Volume 146, Issue 1, Pages 116-123 (Paper No 437) • Cho, H & Altan, T "Determination of Flow Stress and Interface Friction at Elevated Temperatures by Inverse Analysis Technique" submitted to JMPT, Aug, 2004 (Paper No 520) • Cho, H., Ngaile, G and Altan, T "Simultaneous Determination of Flow Stress and Interface Friction by Finite Element Based Inverse Analysis Technique, annals of CIRP, v.1, 2003, p.221 (Paper No 516) © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 15 Tests to Evaluate Lubricants for Stamping / Hydroforming –The Guiding Zone Test ERC NSM - Friction Test for the Guiding Zone This test is based on pressurizing the tubular specimen to the required pressure level and pushing it through a cylindrical die This tooling uses viscous material to pressurize the tube instead of hydraulic oil © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 16 ERC Tests to Evaluate Lubricants for Stamping / Hydroforming –The Expansion Zone Test NSM Die Protrusion Height indicates Lubricant Performance α Protrusion height PH [mm] 72.5 Tube Specimen material SS304 72 71.5 Increasing interface friction 71 70.5 70 69.5 69 PH 68.5 68 Lub A Lub E Lub D Lub B No Lub Lubricants © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 17 ERC Tests to Evaluate Lubricants for Stamping / Hydroforming –The Guiding / Expansion zone TestsNSM List of Recently Published Reports and Papers • Report No THF/ERC/NSM-04-R-44 entitled “Improvement of Tribological Conditions in Tube Hydroforming by Using Textured Tubes” (2004) • Report No THF/ERC/NSM-04-R-14 (confidential / available only to Crompton Corp.) entitled “Evaluation of Crompton Lubricant for THF” (2004) • Report No THF/ERC/NSM-03-R-90 entitled “Enhancement of Tribological Conditions in Tube Hydroforming” (2003) • Report No THF/ERC/NSM-02-R-91(confidential / available only to Crompton Corp.) entitled “Evaluation of Crompton Lubricant for Tube Hydroforming” (2002) • Report No THF/ERC/NSM-02-R-44 entitled “Flow Stress Determination & Lubricant Evaluation for Hydrofoming of Aluminum Alloy Tubes” (2002) • Report No THF/ERC/NSM-02-R-35 entitled “Evaluation of Lubricants for Tube Hydroforming” (2002) • Kim, H., and Altan, T “Improvement of Tribological Conditions in Tube Hydroforming by Using Textured Tubes”, submitted to Proceedings of the NSF Grantee's Conference, Scottsdale, Arizona, January 2005 (Paper No 551) • Ngaile, G., Gariety, M., and Altan, T "Enhancing Tribological Conditions in Tube Hydroforming by Using Textured Tubes", submitted to ASME Journal of Tribology, February 2004 (Paper No 524) • Ngaile, G., Jaeger, S., and Altan T "Lubrication in Tube Hydroforming-Part I., Transition and Expansion Zones", Journal of Materials Processing Technology, Volume 146, Issue , Pages 108-115 (Paper No 436) • Siegert, K., et al "Evaluation of Lubrication in Tube Hydroforming", Production Engr., vol X, Nr 1, 2003, p.23 (Paper No 529) © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 18 CONCLUSIONS ERC NSM We are continuously looking for : • Industry cooperation and potential applications of our testing methods for lubricant selection and evaluation • Industry support, suggestions and interest are most welcome Contacts: Hyunok Kim, GRA (kim.1628@osu.edu, 614-292-3736) Taylan Altan, Professor (altan.1@osu.edu, 614-292-5063) © Copyright Engineering Research Center for Net Shape Manufacturing, 2005 All rights reserved 19