Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg



Lubricant free forming with tailored tribological conditions (DFG - SPP 1676)



Project Status: Active

Members


 

Motivated by a growing environmental awareness and increasing demand for an efficient usage of resources, this research project aims to realize lubricant-free sheet metal forming processes. With conventional deep drawing tools the direct contact between tool and sheet surface leads to increasing wear and a decrease in part quality. In order to react to these consequences of lubricant abandonment, tool-sided surface modifications are developed to adjust the friction conditions locally. Using aluminum alloys as sheet material adhesion was identified as the main friction mechanism. Applying a ta-C-coating on the tool surface could stop adhesion and leads to a decrease of friction coefficient of 70 % compared to metallic bright contact. Laser generated structures on uncoated surfaces reduce adhesion due to a decreased real contact area. At the same time, the amount of abrasion increases due to sharp edges on the structural elements. In an inverse approach, dry deep drawing is modeled numerically to derive the local requirements for surface properties of different tool regions. Using the knowledge gained during numerical simulation and laboratory experiments a tailored tool is developed and tested in a real deep drawing process.

 The projekt is part of the priority programm SPP1676. Further information can be found here.

 


Research Groups


Publications

    2018

    • Tenner (geb. Steiner), J.; Häfner, T.; Rothammer, B.; Krachenfels, K.; Zhao, R.; Schmidt, M.; Tremmel, S.; Merklein, M.:
      Influence of laser generated micro textured coated tool surfaces on dry deep drawing processes.
      Dry Metal Forming Open Access Journal 4(2018), pp. 35-46

    2017

    • Tenner (geb. Steiner), J.; Almohallami, A.; Arghavani, M.; Böhermann, F.; Freiße, H.; Herrmann, M.; Mousavi, S. A.; Schöler, S.; Scholz, P. ; Teller, M.; Umlauf, G.; Wulff, D.; Yilkiran, D.; Maier, H.J.:
      How dry is dry? - A critical analysis of surface conditions used in dry metal forming.
      Dry Metal Forming - Open Access Journal 3(2017), pp. 90-94

    • Tenner (geb. Steiner), J.; Häfner, T.; Zhao, R. ; Andreas, K.; Schmidt, M.; Tremmel, S.; Merklein, M.:
      Analysis of tool-sided surface modifications for dry deep drawing of deep drawing steel and aluminum alloys in a model process.
      Dry Metal Forming - Open Access Journal 3(2017), pp. 30-40

    • Häfner, T.; Heberle, J.; Hautmann, H.; Zhao, R.; Tenner (geb. Steiner), J.; Tremmel, S.; Merklein, M.; Schmidt, M.:
      Effect of picosecond laser based modifications of amorphous carbon coatings on lubricant-free tribological systems .
      In: (Edtr.): Proceedings of LPM - the 18th International Symposium on Laser Precision, 2017, published

    • Tenner (geb. Steiner), J.; Andreas, K.; Radius, A.; Merklein, M.:
      Numerical and experimental investigation of dry deep drawing of aluminum alloys with conventional and coated tool surfaces.
      In: (Edtr.): International Conference on the Technology of Plasticity (ICTP), 2017, accepted

    • Zhao, R.; Tenner (geb. Steiner), J.; Andreas, K.; Merklein, M.; Tremmel, S.:
      Investigation of tribological behaviour of a-C:H coatings for dry deep drawing of aluminium alloys.
      Tribology International (2017), published

    2016

    • Tenner (geb. Steiner), J.; Zhao, R.; Tremmel, S.; Merklein, M.:
      Investigation of Tribological Behavior of Carbon Coatings in Dry Sheet Metal Froming.
      In: K. Bobzin, K.-D. Bouzakis, B. Denkena, H. J. Maier, M. Merklein (Edtr.): The "A" Coatings Conference Proceedings, PZH Verlag, 2016, pp. 153-160

    • Zhao, R. ; Tenner (geb. Steiner), J.; Andreas, K.; Merklein, M.; Tremmel, S.:
      Investigation of Tribological Behaviour of a-C:H Coatings for Dry Deep Drawing of Aluminium Alloys.
      In: H. Ronkainen (Edtr.): The 17th Nordic Symposium on Tribology - NORDTRIB 2016, Abstract Programme, 2016, pp. 145

    • Tenner (geb. Steiner), J.; Andreas, K.; Merklein, M.:
      Investigation of surface finishing of carbon based coated tools for dry deep drawing of aluminium alloys.
      In: ASMET (Edtr.): Proc. Int. Deep Drawing Research Group Conf. , 2016, pp. 679-688

    • Merklein, M.; Schmidt, M.; Tremmel, S.; Andreas, K.; Häfner, T.; Zhao, R.; Tenner (geb. Steiner), J.:
      Tailored modifications of amorphous carbon based coatings for dry deep drawing.
      Dry Metal Forming - OAJ FMT (2016), pp. 25-39

    • Tenner (geb. Steiner), J.; Andreas, K.; Merklein, M.:
      Investigation of surface finishing of carbon based coated tools for dry deep drawing of aluminium alloys.
      IOP Conference Series: Materials Science and Engineering 159(2016)1, pp. 12022_1-10

    2015

    • Merklein, M.; Schmidt, M.; Tremmel, S.; Wartzack, S.; Andreas, K.; Häfner, T.; Zhao, R.; Tenner (geb. Steiner), J.:
      Investigation of Tribological Systems for Dry Deep Drawing by Tailored Surfaces.
      Dry Metal Forming - OAJ FMT 1(2015), pp. 42-56

    • Merklein, M.; Andreas, K.; Tenner (geb. Steiner), J.:
      Influence of Tool Surface on Tribological Conditions in Conventional and Dry Sheet Metal Forming.
      International Journal of Precision Engineering and Manufacturing - Green Technology 2(2015)2, pp. 131-137

    • Merklein, M.; Affronti, E.; Tenner (geb. Steiner), J.:
      Numerical investigation of dry and lubricated sheet metal forming processes.
      In: Aldo Ofenheimer, Cecilia Poletti, Daniela Schalk-Kitting, Christof Sommitsch (Edtr.): Key Engineering Materials, 2015, pp. 1029-1035

    • Merklein, M.; Schmidt, M.; Wartzack, S.; Tremmel, S.; Andreas, K.; Häfner, T.; Zhao, R.; Tenner (geb. Steiner), J.:
      Development and Evaluation of Tool Sided Surface Modifications for Dry Deep Drawing of Steel and Aluminum Alloys.
      Dry Metal Forming Open Access Journal 2(2015), published

    • Tenner (geb. Steiner), J.; Merklein, M.:
      Investigation of Influencing Parameters for Tribological Conditions in Dry Forming Processes.
      Acta Metallurgica Sinica English Letters 28(2015)12, pp. 1435-1441

    2014

    • Andreas, K.; Tenner (geb. Steiner), J.; Vierzigmann, U.; Merklein, M.; Tremmel, S.; Zhao, R.:
      Innovative Tribological Systems in Sheet Metal Forming - Revolution in the Press Shop?.
      In: Bouzakis, K.-D.; Bobzin, K.; Denkena, B.; Merklein, M. (Edtrs.): Proc. 11th Int. Conf. THE "A" Coatings in Manufacturing Engineering, 2014, pp. 87-96

    Letztes Update: 20.10.2017