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Process-Integrated Lubrication in Sheet Metal Forming

Research output: Contribution to journalArticleResearchpeer review

Authors

  • Roland Lachmayer
  • Bernd Arno Behrens
  • Tobias Ehlers
  • Philipp Müller
  • Philipp Althaus
  • Marcus Oel
  • Ehsan Farahmand
  • Paul Christoph Gembarski
  • Hendrik Wester
  • Sven Hübner

Details

Original languageEnglish
Article number121
Number of pages24
JournalJournal of Manufacturing and Materials Processing
Volume6
Issue number5
Early online date14 Oct 2022
Publication statusPublished - Oct 2022

Abstract

The deep-drawability of a sheet metal blank is strongly influenced by the tribological conditions prevailing in a deep-drawing process. Therefore, new methods to influence the tribology represent an important research topic. In this work, the application of a process-integrated lubrication in a deep-drawing process is investigated. Most promising geometries of the lubrication channels and outlet openings are first identified by means of numerical simulation at the example of a demonstrator process. Cylindrical test specimens with the specified channel geometries are additively manufactured and installed in a strip drawing test stand. Additive manufacturing enables the possibility of manufacturing complex channel geometries which cannot be manufactured by conventional methods. A hydraulic metering device for conveying lubricant is connected to the cylindrical test specimens. Thus, hydraulically lubricated strip drawing tests are performed. The tests are evaluated according to the force curves and the fluid mechanical buildup of pressure cushion. The performance of process-integrated lubrication is thus analyzed and evaluated. By means of a coupled forming and SPH simulation, the lubrication channels could be optimally designed. From the practical tests, it could be achieved that the drawing force decreases up to 27% with pressure cushion build up. In this research, a hydraulic lubrication in the area of highest contact normal stresses is the most optimal process parameter regarding friction reduction.

Keywords

    additive manufacturing (AM), deep-drawing, design for additive manufacturing (DfAM), functional integration, laser powder bed fusion (LPBF), lubrication

ASJC Scopus subject areas

Cite this

Process-Integrated Lubrication in Sheet Metal Forming. / Lachmayer, Roland; Behrens, Bernd Arno; Ehlers, Tobias et al.
In: Journal of Manufacturing and Materials Processing, Vol. 6, No. 5, 121, 10.2022.

Research output: Contribution to journalArticleResearchpeer review

Lachmayer, R, Behrens, BA, Ehlers, T, Müller, P, Althaus, P, Oel, M, Farahmand, E, Gembarski, PC, Wester, H & Hübner, S 2022, 'Process-Integrated Lubrication in Sheet Metal Forming', Journal of Manufacturing and Materials Processing, vol. 6, no. 5, 121. https://doi.org/10.3390/jmmp6050121
Lachmayer, R., Behrens, B. A., Ehlers, T., Müller, P., Althaus, P., Oel, M., Farahmand, E., Gembarski, P. C., Wester, H., & Hübner, S. (2022). Process-Integrated Lubrication in Sheet Metal Forming. Journal of Manufacturing and Materials Processing, 6(5), Article 121. https://doi.org/10.3390/jmmp6050121
Lachmayer R, Behrens BA, Ehlers T, Müller P, Althaus P, Oel M et al. Process-Integrated Lubrication in Sheet Metal Forming. Journal of Manufacturing and Materials Processing. 2022 Oct;6(5):121. Epub 2022 Oct 14. doi: 10.3390/jmmp6050121
Lachmayer, Roland ; Behrens, Bernd Arno ; Ehlers, Tobias et al. / Process-Integrated Lubrication in Sheet Metal Forming. In: Journal of Manufacturing and Materials Processing. 2022 ; Vol. 6, No. 5.
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AU - Behrens, Bernd Arno

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AU - Müller, Philipp

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AU - Oel, Marcus

AU - Farahmand, Ehsan

AU - Gembarski, Paul Christoph

AU - Wester, Hendrik

AU - Hübner, Sven

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