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RESEARCH
Keywords:
Multistage ironing
Lubricant
Roughness
Die
Punch
Corresponding author:
Dragan Adamovi
Faculty of Engineering,
University of Kragujevac,
Sestre Janjic 6,
Kragujevac, Serbia.
E-mail: adam@kg.ac.rs
ABSTRACT
If it is needed to achieve a higher strain rate during the ironing process, which is
possible without inter-stage annealing, the ironing is performed in succession
through multiple dies. During that process, changes of friction conditions occur due
to the change of contact conditions (dislodging of lubricants, changes of surface
roughness, formation of friction junctions, etc.). In the multistage ironing, after each
stage, the completely new conditions on the contact surfaces occur, which will
significantly affect the quality of the workpiece surface. Lubricant has a very
important role during the steel sheet metal ironing process; to separate the sheet
metal surface from the tool and to reduce the friction between the contact surfaces.
The influence of tribological conditions in ironing process is extremely important and
it was a subject of study among researches in recent years, both in the real processes
and on the tribo-models. Investigation of tribological conditions in the real processes is
much longer and more expensive, so testing on the tribo-models is more frequent.
Experimental research on the original tribo-model presented in this paper was
aimed to indicate the changes that occur during multistage ironing, as well as to
consider the impact of some factors (tool material, lubricant on die and punch) on
increase or decrease of the sheet metal surface roughness in ironing stages.
2015 Published by Faculty of Engineering
1. INTRODUCTION
The main objective of metal forming is to obtain
the object of a certain shape that depends on the
geometry and shape of the tool.
The contact surface in the deformation process
depends on the geometry of the contact, which
significantly affects friction and wear
parameters, as well as the nominal and real unit
pressures. The shape of the contact surface
(dimensions, curvature radius, change of cross
section) affects the type of contact and the stress
215
217
3. RESEARCH RESULTS
At multiphase drawing of steel sheet metals,
after the very first sliding, a very significant
reduction of roughness on die side occurs (Fig.
2). With the increase of number of slidings,
larger or smaller increase of roughness occurs in
dependence on the applied lubricant. The largest
increase of roughness occurs at lubricant M2
which was applied only before the beginning of
drawing. It is assumed that, in the absence of
lubricant, the resulting abrasive particles
significantly influence the increase of roughness.
It would be interesting to observe that after the
second sliding, the friction coefficient M
decreases with simultaneous increase of sheet
metal roughness [9]. That can be explained by
more favourable apportionment of lubricant in
pockets of roughnesses.
218
1.4
0148P3
Lubricant
on die
M1
M2
M3
M4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
II
III
IV
Number of slidings, N
2
0
-2
-4
0.0
0.2
0.4
0.6
0.8
1.0
1.2
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
I ironing, Ra = 0.20 m
0.1mm
4
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
II ironing, Ra = 0.39 m
4
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.1mm
mm
219
2
0
-2
-4
0.0
0.2
0.4
0.6
0.8
1.0
1.2
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.1mm
mm
I ironing, Ra = 0.152 m
4
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.1mm
mm
II ironing, Ra = 0.260 m
0.1mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
220
1.4
0148P3
Lubrincant
on die
1.2
1.0
M1
M2
M3
M4
0.8
0.6
0.4
0.2
0.0
0
II
III
IV
0
I
II
III
IV
Tool material-M/I: AC/AC Tool material-M/I: TM/AC
Number of slidings, N
1.2
0148P3
Lubrincant on punch
1.0
M2
M4
0148P3
Holding force
FD = 7.4 kN
1.2
1.0
0.8
FD = 14.8 kN
0.6
0.4
0.2
0.0
II
III
IV
Number of slidings, N
0.8
0.6
0.4
0.2
0.0
II
III
IV
II
III
IV
Number of slidings, N
0
-2
-4
0.0
0.2
0.4
0.6
0.8
1.0
1.2
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.1mm
mm
I ironing, Ra = 0.419 m
0.1mm
4
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
II ironing, Ra = 0.508 m
0.1mm
4
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
mm
222
0
-2
-4
0.0
0.2
0.4
0.6
0.8
1.0
1.2
0.1mm
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.1mm
mm
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0.1mm
4.0
mm
I ironing, Ra = 0.104 m
4
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.1mm
mm
II ironing, Ra = 0.096 m
4
2
0
-2
-4
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.1mm
mm
0.25 mm
2 m
2 m
2 m
Fig. 9. 2D roughness form and photomicrographs of steel sheet metal on punch side at different stages of ironing
(lubricant on die/punch M2/S).
0.25 mm
Ironing direction
0.25 mm
0148P3, =3.5 %, M2
0148P3, = 20.5 %, M2
0148P3, = 45.5 %, M2
a)
b)
c)
Fig. 10. Characteristic surface looks formed after sheet metal ironing: a) smooth surface, b) scratched surface, c)
gouged surface.
223
[4] .. : , ,
, 1962.
Acknowledgment
The part of this research is supported by Ministry
of Education and Science, Republic of Serbia,
Grant TR32036 and TR34002
REFERENCES
224
4. CONCLUSION
[2] ..
:
p
, , , 1965.
Trybologia,
WNT,