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| موضوع: كتاب Tribological Technology in Sheet Metal Forming الإثنين 04 يوليو 2022, 1:36 am | |
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أخواني في الله أحضرت لكم كتاب Tribological Technology in Sheet Metal Forming Materials Forming, Machining and Tribology Akira Azushima
و المحتوى كما يلي :
Contents 1 Direct Observation of Lubrication Behavior . 1 1.1 Direct Observation in Drawing Between Flat Dies 1 1.1.1 Apparatus for Direct Observation and Experiments 2 1.1.2 Effect of Average Pressure on Coefficeint of Friction . 3 1.1.3 Friction Model in Lower Average Contact Pressure 7 1.1.4 Effect of Surface Topography of Workpiece 12 1.2 Direct Observation in Sheet Drawing 16 1.2.1 Apparatus for Direct Observation . 17 1.2.2 Micro-plasto-Hydrodynamic Lubrication . 18 1.3 In Lubro 3D Measurement of Oil Film Thickness at Interface 21 1.3.1 In Lubro Fluorescence Microscopy 22 1.3.2 In Lubro Measurement of Oil Film Thickness in Drawing Between Flat Dies 24 1.3.3 In Lubro Measurement of Oil Film Thickness in Sheet Drawing . 28 References 32 2 Friction Behavior in Drawing Between Flat Dies . 35 2.1 New Tribo-simulator Controlled by Computer 36 2.1.1 New Tribo-simulator 36 2.1.2 Experimental and Results 38 2.2 Effect of Lubricant Viscosity and Additive on Coefficient of Friction . 39 2.2.1 Experimental . 39 2.2.2 Results and Discussion 39 2.3 Effect of Yield Stress on Coefficient of Friction . 42 2.3.1 Experimental . 42 2.3.2 Results and Discussion 42 viiviii Contents 2.4 Effect of Bulk Deformation of Specimen on Coefficient of Friction . 43 2.4.1 New Testing Method for Elongation Control of Specimen . 43 2.4.2 Experimental . 44 2.4.3 Results and Discussion 45 2.5 Effect of Back Tension on Coefficient of Friction . 46 2.5.1 New Testing Method for Back Tension Control and Experimental . 46 2.5.2 Results and Discussion 47 References 49 3 Friction Behavior in Flat Sliding 51 3.1 Apparatus and Characteristic of Flat Sliding 51 3.2 Effect of Surface Topography on Coefficient of Friction of Steel Sheet 53 3.2.1 Experimental . 53 3.2.2 Results 55 3.2.3 Discussion . 59 3.3 Effect of Contact Length of Die on Coefficient of Friction of Steel Sheet 60 3.3.1 Experimental . 60 3.3.2 Results 61 3.3.3 Discussion . 66 3.4 Friction Behavior in Flat Sliding of Plated Steel Sheet . 68 3.4.1 Experimental . 68 3.4.2 Results and Discussion 69 3.5 Friction Behavior in Flat Sliding of Aluminum Alloy Sheet . 71 3.5.1 Experimental . 72 3.5.2 Results and Discussion 72 References 74 4 Friction Behavior in Repeatedly Flat Sliding . 75 4.1 Apparatus and Characteristics 75 4.2 Effect of Yield Stress on Coefficient of Friction . 78 4.2.1 Experimental . 79 4.2.2 Results 79 4.2.3 Discussion . 82 4.3 Friction Behavior of Flat Sliding of Plated Steel Sheet . 84 4.3.1 Experimental . 85 4.3.2 Results and Discussion 85 References 89Contents ix 5 Friction Behavior in Tension-Bending . 91 5.1 Surface Behavior of Specimen with Dull Surface in Sliding Under Tension-Bending . 92 5.1.1 Apparatus . 92 5.1.2 Experimental . 93 5.1.3 Results and Discussion 94 5.2 Surface Behavior of Specimen with Smooth Surface in Sliding Under Tension-Bending 97 5.2.1 Experimental . 97 5.2.2 Results and Discussion 98 5.3 Direct Observation of Micro-contact Behavior at Interface in Sliding Under Tension-Bending 102 5.3.1 Apparatus . 103 5.3.2 Experimental . 104 5.3.3 Results and Discussion 104 5.4 Coefficient of Friction by Tribo-simulator Controlled by Computer 106 5.4.1 Apparatus . 107 5.4.2 Experimental . 108 5.4.3 Results and Discussion 108 References 110 6 Friction Behavior in Ironing 111 6.1 Coefficient of Friction by Fundamental Tribo-simulators . 112 6.1.1 Experimental . 112 6.1.2 Results 113 6.1.3 Effect of Chemical Composition on Coefficient of Friction by SRV Test 115 6.2 Coefficient of Friction of Commercial Oils by New Tribo-simulator 117 6.2.1 New Tribo-simulator 118 6.2.2 Coefficient of Friction of Commercial Oils by New Tribo-simulator . 121 6.2.3 Coefficient of Friction of Surface Coated Die by New Tribo-simulator . 124 References 126 7 FEM Analysis of Friction Behavior in Deep Drawing . 127 7.1 Measurement of Punch Load in Deep Drawing . 128 7.1.1 Experimental . 128 7.1.2 Results and Discussion 130 7.2 FEM Analysis of Punch Load in Cylindrical Cup Deep Drawing 132 7.2.1 Analytical Method 132 7.2.2 Results and Discussion 136 7.3 Effect of Friction Behavior on Formability in Deep Drawing 138x Contents 7.3.1 Measurement of Formability in Semi-spherical Cup Deep Drawing . 138 7.3.2 FEM Analysis of Formability in Semi-spherical Cup Deep Drawing . 143 7.3.3 FEM Analysis of Fracture in Semi-spherical Cup Deep Drawing 145 References 150 8 Tribological Numerical Modeling in Sheet Drawing 151 8.1 Coefficient of Friction 152 8.1.1 Method to Obtain Coefficient of Friction Using Tribo-simulator . 152 8.1.2 Method to Obtain Coefficient of Friction Using Normal and Drawing Forces 152 8.1.3 Coefficient of Friction Calculated from Normal and Drawing Forces Measured 153 8.2 New Coefficient of Friction 155 8.3 Tribological Numerical Modeling for Coefficient of Friction in Sheet Drawing . 155 8.3.1 Lubrication Models . 155 8.3.2 Mixed Lubrication of Hydrodynamic Lubrication, Hydrostatic Lubrication and Boundary Lubrication 160 8.4 Inlet Oil Film Thickness . 161 8.5 Tribological Numerical Modeling in Sheet Drawing . 165 8.5.1 Formulation of Area Ratio of Boundary Lubrication Region . 165 8.5.2 Coefficient of Friction in Tribological Numerical Modeling 165 8.6 Numerical Calculation of Coefficient of Friction 166 8.6.1 Calculation Conditions 166 8.6.2 Calculation Results and Discussion 166 8.7 Remarks 167 References 168 9 Simulation of Seizure in Sheet Metal Forming . 169 9.1 Simulation of Seizure in Flat Sliding Test 170 9.1.1 Introduction of Some Data in Chap. 3 170 9.1.2 Experimental . 171 9.1.3 Results and Discussion 173 9.1.4 Remarks . 175 9.2 Simulation of Seizure in Repeatedly Flat Sliding Test 176 9.2.1 Introduction to Some Data in Chap. 4 176 9.2.2 Effect of Yield Stress on Seizure by Repeatedly Flat Sliding 177 9.3 Simulation of Seizure in Ironing 179 9.3.1 New Tribo-simulator 180Contents xi 9.3.2 Evaluation of Commercial Oils for Ironing by New Tribo-simulator . 182 9.3.3 Evaluation of Commercial Lubricants for Ironing Using Surface Coated Die by New Tribo-simulator 185 9.3.4 Evaluation of Non-chlorine Lubricant with High Lubricity for Ironing by New Tribo-simulator . 188 9.3.5 Development of Non-chlorine Lubricant with High Lubricity for Ironing by New Tribo-simulator . 190 References 192 10 Lubrication in Hot Stamping . 193 10.1 Development of Tribo-simulator for Lubrication in Hot Stamping . 194 10.1.1 Test Machine . 194 10.1.2 Property of Infrared Image Furnace 195 10.1.3 Measurement of Coefficient of Friction 197 10.2 Lubrication in Hot Stamping of Aluminum-Coated 22MnB5 Steel . 203 10.2.1 Experimental . 204 10.2.2 Results of Heating 205 10.2.3 Results of Coefficient of Friction Under Dry Condition 206 10.2.4 Results of Coefficient of Friction Under Lubricated Condition 209 10.2.5 Effect of Surface Coated Die on Coefficient of Friction Under Dry Conditions . 213 10.2.6 Thermal Behavior Under Dry and Lubricated Conditions . 216 10.2.7 Development of New Lubricant for Hot Stamping of Al-Coated 22MnB5 Steel 223 10.2.8 Adhesion Behavior of Aluminum on Die Surface 227 10.3 Lubrication in Hot Stamping of AA7075 Aluminum Alloy . 231 10.3.1 Experimental . 232 10.3.2 Effect of Composition of Lubricant on Coefficient of Friction . 233 10.3.3 Effect of Viscosity of Synthetic Ester Oil on Coefficient of Friction 233xii Contents 10.3.4 Effect of Normal Load on Coefficient of Friction 234 10.3.5 Effect of Extreme Pressure Additive on Coefficient of Friction . 235 10.3.6 Effect of Solid Lubricant on Coefficient of Friction 237 References 238 Index Index A AA7075 Aluminum alloy, 232, 234–236 Abrasion, 211, 220 Additive, 39–41, 72–74, 108, 109, 111, 115, 117, 130, 132–136, 138, 139, 141, 142, 180, 201, 235, 237 Adhered aluminum, 209, 212, 227–231 Adhered aluminum layer, 209, 212, 221 Adhesion, 71, 183, 184, 209, 215, 216, 227, 231 Adhesion force, 159 Age hardening type aluminum, 232 Aging heat treatment, 232 Aluminum adhesion layer, 212, 221 Aluminum adhesion thickness, 216 Aluminum-coated HSS, 203 Aluminum coating layer, 209 Aluminum-coated 22MnB5 steel, 203, 213 Amonton-Coulomb’s friction model, 10–12 Ar atmosphere, 204 Asperity, 5, 8–10, 13, 25, 41, 43, 56, 82, 86, 89, 102, 103 Asperity flattening, 8–10, 12, 26, 43, 46, 47, 59, 83, 104–106 Austenite, 193 Average coefficient of friction, 120, 166, 214, 215 Average contact pressure, 2–8, 15–17, 25, 35, 36, 94, 97–101 Average normal pressure, 9–12, 157, 158, 167 B Back tension, 37, 46–49, 52, 76, 92–100, 104–106, 133 Ball on disk friction test, 115 Base oil, 39–42, 44, 46, 55, 69, 72–74, 85, 93, 97, 104, 108, 130, 132, 141, 142, 153, 154, 171, 235, 236 Bending, 91–93, 96, 97, 99, 102–109, 130, 133, 139, 169 Binary lubricant, 190, 191 Blank holder force, 130–132, 136–138, 141–143, 145, 148, 149 Boundary agent, 41 Boundary-hydrodynamic lubrication, 102 Boundary-hydrostatic-micro-plastohydrodynamic lubrication, 7 Boundary lubrication, 4, 5, 8, 15, 40, 41, 47, 56, 57, 59, 66, 67, 82, 157–160, 167 Boundary lubrication region ratio, 157, 158, 160, 165–167 Boundary shear stress, 157 Bulk deformation, 6, 8–10, 12, 20, 43, 44, 46 C Chlorine-free lubricant, 180 Chlorine lubricant, 112, 115, 117, 121, 182, 188, 190 Clearance, 130, 131 Closed lubricant pool, 4–6, 86, 89 Coated die, 187, 214–216 Coefficient of friction, Commercial lubricant, 112, 117, 120, 121, 182, 186, 223–226, 228 Compression load, 194, 195, 197, 198, 200–204, 206, 213, 218, 224, 227 Compression-sliding test, 217, 221 Compression test, 9, 216, 218, 219, 221, 222 Computer simulation, 42, 78 Constant friction factor model, 8, 11, 12 Constitutive equation, 151 Contact length, 55, 60–67, 69, 72, 75, 79, 85, 171, 172, 177 Contour map, 147, 148 Cooling rate, 222, 223 Cylinder cup deep drawing, 127, 128–133, 136 D Deep drawing, 91, 127–129, 132, 133, 136, 138, 139, 143, 145, 148 Deep drawing test, 35, 127, 129–131, 138–140, 145, 148, 203 Die angle, 3, 17, 97, 153 Die pressure, 197, 199, 202, 203 Die wear, 213 Direct observation, 1, 2, 17–20, 28, 92, 102 Draw bead test, 35 Drawing between flat dies, 1, 2, 15, 25, 35, 43, 44, 47, 51, 133–135, 138, 139, 143, 148, 167 Drawing distance, 197, 200, 209, 210, 213, 214, 218, 219, 221, 222, 224–226, 228–230, 233–238 Drawing force, 3, 9, 14, 152, 153, 155, 203 Drawing load, 3, 38, 39, 42, 45, 47, 69, 85, 92, 97, 200 Drawing ratio, 130, 139–146, 148, 149 Drawing speed, 3, 8, 17, 18, 20, 38, 39, 42, 44, 47, 69, 85, 108, 153, 154, 166, 167, 194, 195, 197, 200, 202–204, 213, 224, 227, 232 Drawing tension, 197 Drawing test between flat dies, 35, 169 Dry condition, 152, 197, 198, 203, 206, 207, 209, 211–213, 216–223, 227–229, 231 Dull surface, 53, 55–64, 66–68, 92, 93, 96, 102, 104, 128, 138, 170–175 E EDX analysis, 208, 209, 211, 212, 214, 215, 220, 228, 231 EDX image, 220 EG steel, 68–71, 85–88 Elastic-plastic body, 135, 143 Elongation, 39, 42, 44–46, 72, 94, 97–99, 104, 108 Elongation strain, 94–96 Energy equation, 163 Equilibrium equation, 155 Erichsen tester, 128–130, 136 Extreme pressure additive, 111, 112, 115–118, 120, 179, 182, 190, 235–237 Extreme pressure agent, 41, 235, 237 F FEM analysis, 51, 127, 132, 133, 136–138, 143–145, 147, 148, 150–152, 155, 168, 170, 176 Flat die drawing, 38, 39, 42, 69, 85 Flat die drawing test, 2 Flat die sliding Flat die sliding test Flattening asperity, 66, 67 Flat tool drawing, 8, 9, 25 Flat tool sliding Flow stress, 152, 203 Fluid film, 155 Fluorescence dye Fluorescence microscope, 23 Formability, 127, 138–141, 143 Forward tension, 119, 120, 122, 125, 181–183, 187 Fracture, 140, 143, 145, 148 Frictional force, 10, 127, 138, 158–160 Frictional shear stress, 10, 159, 161 Friction factor, 12 Friction pick up, 39 Front tension, 118, 119, 181, 194 Furnace temperature, 194, 196, 198, 200, 202, 205 H Hardened martensite, 193 Hard film, 213 Hat bending test, 216 Heating time, 195, 196 Heat transfer, 216, 218, 219, 221–223 Heat transfer coefficient, 216 High Speed Steel (HSS), 2, 204Index 241 Hot flat drawing test, 193, 194, 213, 216, 223, 224, 227, 232, 233 Hot forging, 223–226, 228 Hot stamping, 193–195, 203, 206, 209, 211–213, 216, 218, 223–227, 231–233, 235, 236 Hydrodynamic lubrication, 17, 20, 57, 58, 102, 155–158, 160, 167 Hydrophilic polymer, 224, 225, 228 Hydrostatic-boundary lubrication, 5, 6, 15 Hydrostatic lubrication, 22, 40, 47, 53, 57, 59, 83, 89, 159, 160, 173, 175 Hydrostatic pressure, 4–6, 17, 18, 46, 56, 59, 89, 159 I Indentation, 18 Infrared image furnace, 194, 195, 197, 204, 232 Inlet oil film thickness, 161–167 In-site direct observation Ironing, 111, 112, 114, 115, 117–120, 124, 126, 131, 169, 179–182, 185, 186, 188, 190 J Junction growth, 41 L Lateral load, 3, 51–53, 75–77, 79, 170, 176, 177 Limiting breaking blank holder force, 141, 142, 144, 146 Limiting breaking height, 140 Limiting forming height, 141, 142, 144, 146 Lubricant viscosity, 39–41, 53, 56, 59, 61, 62, 64, 69, 95, 96, 130, 132, 162, 163 Lubricated condition, 152, 197, 200, 203, 204, 209, 211, 212, 216–224, 227–231, 233 M Martensite, 221 Mean coefficient of friction, 134, 135, 198, 199, 201–204, 207, 210, 214, 224, 226, 228–230, 233, 235–238 Mean pressure, 39–41, 43, 47, 51, 53–59, 61–66, 104–110, 133–135, 171–175 Micro-Plasto Hydrostatic Lubrication (µPHL), 1, 7, 17, 18, 28 Micro-roughening, 4, 7 Mineral base oil, 74 Mineral salt, 224, 225 Mixed lubrication, 40, 41, 47, 53, 56–58, 82, 157–161, 165 22MnB5 steel, 205, 212, 223, 227 Multiple regression analysis, 117 N Newtonian fluid, 162 Newton-Raphson method, 163 Non-chlorine lubricant, 112, 115–119, 121, 181, 182, 188–190 Non-dimensional mean pressure, 47, 51, 53, 170 Normal contact pressure, 2, 4 Normal force, 3, 4, 14, 152, 155 Normal load, 3, 5, 9, 10, 38, 39, 42, 44, 47, 51–53, 55, 61, 69, 72, 75–77, 79–83, 85–88, 92, 112, 114, 115, 119–126, 157–160, 170, 171, 173, 176–178, 180–185, 187, 188, 232, 235 Numerical modeling, 155 Numerical simulation, 35, 39, 102 O Oil film thickness, 8, 21–26, 28, 31, 32, 40, 57, 64, 67, 155, 156, 162, 164–166, 174 Oil pocket, 5, 46, 47, 159, 175 Optical microscope photograph, 173–175 Optical surface photograph, 207, 208, 211 P Paraffinic base oil, 3, 8, 38–42, 44–47, 53, 55, 60, 69, 72, 73, 77, 85, 108, 128, 130, 139, 153, 171, 177 Permeation behavior, 19, 20 Physical simulation, 169 Plastic contact area, 157–159 Plasto-hydrodynamic lubrication (PHL), 17 Poiseuille flow, 156 Poisson ratio, 135, 136, 143 Pressure coefficient of lubricant, 108 Profile meter, 24 Proof stress, 2, 3, 38, 39, 53, 72, 97, 104, 108 Punch load, 127–132, 136–138 Punch stroke, 128–132, 136–138, 140, 145 Pyramidal indentation, 18, 20, 29–32242 Index Q Quenching, 222, 223 R Real contact area, 1, 3–5, 7–12, 15, 17, 19, 20, 25–28, 40, 41, 56, 59, 66, 67, 77, 82, 83, 86, 87, 89, 102, 159, 176, 225 Real contact area ratio, 8, 9, 11, 12, 14–16, 83, 84, 94–96, 165, 166, 178, 179 Recess, 56, 82 Reynolds equation, 20, 22, 83, 155, 162, 163 Rigid body, 155 Rigid-plastic body, 155 Root mean square roughness, 165 Runge-Kutta method, 163 S Scale, 195, 196 Scale layer thickness, 195, 197 Scale thickness, 199, 200 Seizure, 57, 64, 66, 67, 72, 73, 77, 83, 84, 86, 87, 89, 111, 115, 169–176, 178–184, 186–192, 199, 201, 232–235 Seizure resistance, 118, 175, 180–183, 185–190 Semi-angle of die, 161 SEM image, 215, 216 Semi-spherical cup deep drawing, 138–141, 143, 145, 146, 148, 149 SEM micrograph, 208, 209, 211, 212, 220 Shearing, 169 Shear stress, 5, 155–160, 167, 227 Sheet drawing, 1–3, 7, 13, 15, 17, 20, 25, 28, 29, 43, 44, 47, 51, 133, 148, 151–153, 155, 156, 158–161, 163–168 Sheet metal forming, 2, 11, 13, 21, 22, 24, 35, 36, 38, 42, 43, 51, 75, 78, 85, 89, 91, 102, 106, 111, 133, 143, 151, 152, 161, 169, 170, 172, 174–176, 178–180, 182, 184, 186, 188, 190, 192 SKD11 die, 124, 125, 188 SKD61 die, 180, 195, 197, 204, 213, 217, 223, 227, 232 SKD61 roll, 119, 124, 186, 188, 195 Sliding distance, 53, 75, 77, 115, 120–126, 181, 183–189, 195, 196, 198, 200, 206, 207, 210, 218, 219, 222, 224, 227, 229 Sliding under tension-bending, 92, 95, 97, 101, 103, 133–135, 138, 143, 148, 167 Smooth surface, 1, 2, 13, 16, 17, 55, 57–61, 63–67, 97, 102, 104–106, 170–176, 212 Sold lubricant Split-die technique, 152 Springback, 193 SRV friction tester, 112, 114, 115, 117 Stress-strain curve, 136, 143 Stylus surface profile meter, 24 Surface appearance, 66, 67, 79, 92, 93, 97, 99, 104 Surface asperity, 21, 94–96, 99, 101, 102, 212 Surface coated die, 124–126, 176, 180, 186, 188, 213 Surface failure, 80–82, 178 Surface photograph, 15, 16, 93, 120, 121 Surface profile, 8, 24, 68, 85, 97, 99, 100, 128, 204, 205, 209, 211, 212, 221 Surface roughening, 99, 101, 102, 106 Surface texture, 217, 221 Surface topography, 13, 25, 43, 53 Surface treated steel, 68 Swellable mica, 224, 227 Synthetic ester oil, 232–238 T Tangential load, 55, 61, 72, 152, 171, 173 Temperature coefficient of viscosity, 163 Temperature profile, 205, 218, 219, 223 Tensile strength, 39, 42, 44, 46, 53, 55, 60, 68, 70–72, 77, 79–82, 97, 104, 108, 139, 170, 171, 177, 178 Tension bending, 91–93, 95–97, 99, 101–104, 106–109, 127, 130, 133–135, 138, 139, 143, 148, 167 Tension bending type simulator, 92, 93, 97 Tension load, 92, 194, 195, 198, 200, 204 Ternary lubricant, 190, 192 Thermal coated resistance Thermal transfer, 216 Thermal transfer coefficient, 216 Thermocouple, 217 Thin-film boundary lubrication, 9, 56, 173, 175, 176 Thiophene compound, 23, 25 3D-oil film thickness, 22, 25 3D-surface profile, 13, 55, 60, 79, 171, 177 3D-surface topography, 25, 26, 28Index 243 Tool wear, 213 Trapped lubricant, 15, 17, 20, 26, 27, 30, 31 Tribological numerical modeling, 151, 155, 165–168 Tribo-simulator, 2, 8, 35–39, 42–44, 46, 51, 78, 92, 106, 107, 109, 112, 117–121, 124, 126, 127, 133, 138, 143, 148, 152, 155, 169, 180–183, 185, 188, 190, 193, 194, 202, 203, 213, 223, 232 U Uncoated die, 214–216, 223 Uncoated HSS, 203 V VC-SKD11 die Vertical load, 123, 152, 183 Viscosity of lubricant, 19, 20, 55, 57, 60, 128, 129, 139, 154, 162, 163, 171 W Water base lubricant, 224, 225 Water-soluble graphite, 232 Water soluble polymer, 232 Y Yield criterion equation, 10, 11 Yield stress, 2, 10, 35, 42–44, 46, 53, 55, 60, 77–79, 85, 86, 119, 121, 128, 135, 139, 143, 156, 162, 164, 166, 170, 171, 177, 178, 181, 183, 186, 203 Young’s modulus
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