Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

High-Volume Capability of Dry Film Lubricated Aluminium Sheet Metal - Basic Investigations Focused at Tribology, Deep-Drawing Performance and Real-Part Trials

Datum: 13.05.2005


  • Dr.-Ing. Markus Meiler


  • Prof. Dr.-Ing. Dr.-Ing. E.h. mult. Dr.h.c. M. Geiger
  • Prof. Dr.-Ing. H. Hoffmann, TU München

The production of automotive body parts and panels is a very complex process. It starts with the raw material and finally ends in the paint shop. Due to the fact that aluminium sheet metal has to be lubricated before forming the whole process-chain has to be considered. Lubricants have to protect the material?s surface, reduce friction whilst drawing the panels and should not compromise further treatments. Of course, different types of lubricants show different characteristics. Compared to liquid lubricants dry-film lubricants do not run off the blanks? surface and are distributed homogeneously. This paper shows the effect of lubrication on friction of aluminium sheet metal through several basic experiments and evaluates the different tribological systems. Main focus is the description of an ideal tribological system. Furthermore it describes pros and cons not only for drawing, but also for assembly lines and the painting process. The issues are carried out on stability testings of bonded, riveted and clinched real-part assemblies. Additionally, experiences made in the press shop at BMW?s Dingolfing plant were carried over to a long-term strategy of pre-lubrication of aluminium sheet metal. This includes adhesive compatibility as well as the above mentioned assembly process.