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Abstract
This paper presents a new friction and lubrication test for cold forging. The test allows controlled
variation of the surface expansion in the range 0-2000% the tool temperature in the range 20-
270C and the sliding length between 0 and infinite. Friction is decreasing with increasing
temperature in the range 30-150C. Above this temperature range friction increases. As regards
lubricant performance Lubrication Limit Curves (LLC) are plotted in a sliding length-surface
enlargement diagram with the tooi temperature as a parameter. Larger tool temperature
implies lower acceptable surface expansion and sliding length.
The knowledge about the quantitative influence of Hansen and Bay, /6/,have earlier developed a test
the basic parameters on friction and lubrication in for simulation of processes involving high pressures.
cold forging is very sparse. This is due to the great In that test the cylindrical workpiece was
variety of parameters and the problems of plastically deformed by backwards can extrusion
performing isolated analyses of one individual in a cylindrical die tool and then, under a constant
process parameter like normal pressure, surface load kept at the maximum value, rotating the
expansion, sliding length or sliding velocity in the workpiece together with the die whilst the punch
processes themselves, since varying one para- was kept stationary. The punch nose was designed
meter at a time under controlled conditions is according to the recommendations of the Int.
normally impossible. For this purpose simulation Cold Forging Group, /7/, but with a modified very
tests have to be applied, but although a large short punch land. This means that the friction on
number of tests have been proposed in literature the punch end is measured, i.e. the test area is
/1-6, 8-24, 27/ the development of such tests is still subjected to a normal pressure of 2.0-2.5 times the
insufficient. Critical reviews of existing tests are flow stress of the material but the surface
given in /2,5,22/. Bay, Hansen and Christophenen expansion in the tested area is low.
/1,6/ have earlier developed and tested a
compression-twist test based on simple upsetting The new test, which is schematically outlined in
and subsequent rotation of the circular cylindrical Fig. 1a,is a variant of the above mentioned aiming
specimens against a plane, overhanging tool. This at measuring under large surface expansion
test enables direct measurement of friction as well conditions. The basic test principle is the same, i.e.
as normal stress under conditions corresponding to a backward can extrusion and subsequent rotation
many cold forging operations. Although the test is of the punch with respect to the workpiece and
flexible as regards variation of surface expansion the die under constant load. The difference
and sliding length it is only suitable for testing at between the earlier and the new test is the design
low to medium surface expansion (0-250%) and of the punch nose. In the new test a long punch
thus not satisfactory for simulation of the conditions land is applied thus measuring the friction on this
under heavy deformation processes like backward land as well as on the end face of the punch.
can extrusion, where the surface expansion may Subtracting the torque measured when testing
reach values as high as 2000%. The present paper with zero punch land the net friction on the land is
presents a new test principle, which enables determined. In order to ensure a well defined
testing under such conditions. Besides measuring normal pressure the punch land is slightly conical,
friction it is important to quantify the limits of with an included angle of 4 O . The dimensions of the
lubrication characterized by film breakdown and tools are chosen as follows: die bore 01 1.6 mm,
pick-up of workpiece material on the tool surface diameter of punch nose 09.0 mm implying a
leading to scoring of the workpiece surface. An reduction of r = 0.6, length of punch land 4.5 mm.
important parameter controlling this is the average Fig. 1b shows the geometry of the punch nose in
tool temperature, which in the present test is details.
possible to control within the range 20-270C.
The container is mounted on a specially designed
load cell measuring the punch load. The load cell
Thermocouples
3. TEST PROCEDURE
218
experiments have been performed, at a surface
-E 300
enlargement of AI/Ao = 6 and 20 respectively. For
each tool temperature five experiments were
250 carried out. In the diagram showing the friction
3
w factor the average value and the 95% confidence
E 200 interval is shown. In case of AdAo = 20 minimum
!i friction is found at a temperature between 100 and
$ 150 150C. This corresponds well with earlier obser-
w
vations by the authors using the ring test, /26/.The
results for the test series corresponding to AdAo = 6
are not sufficient in number for determining a
similar optimum in tool temperature. A significant
influence of the surface enlargement on the
0 50 100 150 200 250 300 350 400 friction factor is noted, the friction factor increasing
Nominal punch temperature [C] from a range of 0.04-0.05 to 0.06-0.08 when increa-
sing the surface enlargement from 6 to 20.
Fig. 4: Relationship between nominal and real
punch temperature. 0.20
0.18
z 0.16
Experiments were done 20 seconds after removing E 0.14
the heater. After extruding the can to the desired g 0.12
height, the maximum load was kept while rotating *
g 0.10
the punch. The load, torque and angle of rotation .c
219
25 25 3 I I I I I I
Q Qd 20
620
:5
50 l ; g
v)
5
0
0 50 100 150 200 250 300 0 50 100 150 200 250 300
Sliding length [mm] Sliding length [mm]
Fig. 6: Lubricant performance at a tool tempera- Fig. 9: Lubricant performance at varying tool tem-
ture t = 30C. perature.
25
9 CONCLUSIONS
620
+
cI
The proposed test enables measurement of friction
g 15 and lubricant performance at high surface
expansion. Combined with the earlier proposed
gF 10 compression-twist test using simple upsetting the
two tests cover the whole range of surface
8 expansion and sliding length in cold forging at a
$ 5 normal pressure in the range of 1 flow stress. Further
v) developments should concern testing at higher
0 pressure.
0 50 100 150 200 250 300
Sliding length [mm] ACKNOWLEDGEMENT
Fig. 7: Lubricant performance at a tool tempera- The authors are indebted to M.Sc. Ssren Lassen
ture t = 125C. and M.Sc. Claus B. Andersen for valuable discus-
sions and M.Sc.-students J. H. Larsen and P. Skov-
25 Hansen for their help with the experimental work
3
620 REFERENCES
220
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221