Analysis of the tribological behaviour of polymer composite tool materials for sheet metal forming
Today's automotive industry shifts its focus on customised production, facing an increasing demand for medium and small batch production, where cost-effective manufacturability of sheet metal forming dies comes into the foreground. Filled polymers offer possibilities to fulfil such requirements...
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| Published in | Wear Vol. 268; no. 1; pp. 241 - 248 |
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| Main Authors | , |
| Format | Journal Article |
| Language | English |
| Published |
Amsterdam
Elsevier B.V
04.01.2010
Elsevier |
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| Abstract | Today's automotive industry shifts its focus on customised production, facing an increasing demand for medium and small batch production, where cost-effective manufacturability of sheet metal forming dies comes into the foreground. Filled polymers offer possibilities to fulfil such requirements in the ambit of prototype tools manufacturing or in small batch production of sheet metal components. This paper presents investigations dealing with tribological and tool design aspects of using polymeric materials for sheet metal forming purposes. Friction and wear behaviour of two polymer composites on sheet metal counterface materials have been investigated. A new testing method for wear evaluation of polymeric materials for sheet metal forming using a Strip Drawing Test facility is presented and discussed. A method to predict lifetime of polymeric stamping dies using the linear wear–distance relation
W
l/s measured with the new testing method is also proposed. Significant improvements in friction and wear performance of polymer composites have been observed using sheet materials with structured surfaces. A theoretical model for abrasive friction and wear of polymer composites on sheet metal counterface material pairs has been developed, based on the results obtained by measurement of friction and wear. |
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| AbstractList | Today's automotive industry shifts its focus on customised production, facing an increasing demand for medium and small batch production, where cost-effective manufacturability of sheet metal forming dies comes into the foreground. Filled polymers offer possibilities to fulfil such requirements in the ambit of prototype tools manufacturing or in small batch production of sheet metal components. This paper presents investigations dealing with tribological and tool design aspects of using polymeric materials for sheet metal forming purposes. Friction and wear behaviour of two polymer composites on sheet metal counterface materials have been investigated. A new testing method for wear evaluation of polymeric materials for sheet metal forming using a Strip Drawing Test facility is presented and discussed. A method to predict lifetime of polymeric stamping dies using the linear wear-distance relation W(l/s) measured with the new testing method is also proposed. Significant improvements in friction and wear performance of polymer composites have been observed using sheet materials with structured surfaces. A theoretical model for abrasive friction and wear of polymer composites on sheet metal counterface material pairs has been developed, based on the results obtained by measurement of friction and wear. Today's automotive industry shifts its focus on customised production, facing an increasing demand for medium and small batch production, where cost-effective manufacturability of sheet metal forming dies comes into the foreground. Filled polymers offer possibilities to fulfil such requirements in the ambit of prototype tools manufacturing or in small batch production of sheet metal components. This paper presents investigations dealing with tribological and tool design aspects of using polymeric materials for sheet metal forming purposes. Friction and wear behaviour of two polymer composites on sheet metal counterface materials have been investigated. A new testing method for wear evaluation of polymeric materials for sheet metal forming using a Strip Drawing Test facility is presented and discussed. A method to predict lifetime of polymeric stamping dies using the linear wear–distance relation W l/s measured with the new testing method is also proposed. Significant improvements in friction and wear performance of polymer composites have been observed using sheet materials with structured surfaces. A theoretical model for abrasive friction and wear of polymer composites on sheet metal counterface material pairs has been developed, based on the results obtained by measurement of friction and wear. |
| Author | Liewald, M. de Souza, J.H.C. |
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| Cites_doi | 10.1016/j.wear.2006.10.017 10.1016/S0924-0136(01)00749-X 10.1115/1.1543971 10.1016/j.wear.2007.01.015 10.1016/0043-1648(96)80014-7 10.1016/0043-1648(71)90168-2 10.1016/0301-679X(81)90050-5 10.1016/0043-1648(93)90121-2 |
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| Keywords | Polymer composites Sheet metal forming Friction Wear Rapid tooling Drawing Die forging Tool material Fibre reinforced metal Metal polymer contact Deep drawing Modeling Composite material Sheet metal Tool wear Die Wear test Filled polymers Durability Forming Metal metal contact Experimental study Lifetime Abrasive wear Automobile industry Tribology |
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contact with solid surfaces publication-title: Wear contributor: fullname: Bartenev – volume: 262 start-page: 1407 year: 2007 end-page: 1413 ident: bib9 article-title: Friction and wear performance of pure and glass fibre reinforced poly-ether-imide on polymer and steel counterface materials publication-title: Wear contributor: fullname: Arda – year: 2001 ident: bib24 article-title: Optimizing friction between die and sheet metal publication-title: Second Global Symposium on Innovations in Materials Process & Manufacturing contributor: fullname: Wagner – year: 2005 ident: bib11 article-title: Wear—materials, mechanism and practice publication-title: Tribology of polymeric solids and their composites contributor: fullname: Sinha – start-page: 231 year: 1981 end-page: 243 ident: bib10 article-title: Wear of polymers: an essay on fundamental aspects publication-title: Tribology International contributor: fullname: Briscoe – year: 2006 ident: bib14 article-title: Lubricant test methods for sheet metal forming publication-title: Proceedings NORDTRIB2006 Conference contributor: fullname: Bay – volume: 115 start-page: 97 year: 2001 end-page: 103 ident: bib5 article-title: Rapid tooling approaches for small lot production of sheet-metal parts publication-title: Journal of Materials Processing and Technology contributor: fullname: Sladojevic – volume: 162–164 start-page: 1048 year: 1993 end-page: 1053 ident: bib13 article-title: Case study—an analysis of wear of polymers publication-title: Wear contributor: fullname: Viswanath – year: 2006 ident: bib4 article-title: New design concept for deep drawing prototype tools publication-title: Euro-uRapid 2006 contributor: fullname: Liewald – volume: 9 year: 1997 ident: bib21 article-title: Verschleißprüfstand für die Blechumformung publication-title: Bänder Bleche Rohre contributor: fullname: Schulz-Marner – volume: 125 start-page: 247 year: 2003 end-page: 255 ident: bib6 article-title: Sheet metal forming using polymer composite 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contributor: fullname: Zum Gahr – ident: 10.1016/j.wear.2009.07.017_bib23 – ident: 10.1016/j.wear.2009.07.017_bib16 – volume: 9 year: 1997 ident: 10.1016/j.wear.2009.07.017_bib21 article-title: Verschleißprüfstand für die Blechumformung publication-title: Bänder Bleche Rohre contributor: fullname: Schulte – start-page: 231 year: 1981 ident: 10.1016/j.wear.2009.07.017_bib10 article-title: Wear of polymers: an essay on fundamental aspects publication-title: Tribology International doi: 10.1016/0301-679X(81)90050-5 contributor: fullname: Briscoe – ident: 10.1016/j.wear.2009.07.017_bib18 – volume: 162–164 start-page: 1048 year: 1993 ident: 10.1016/j.wear.2009.07.017_bib13 article-title: Case study—an analysis of wear of polymers publication-title: Wear doi: 10.1016/0043-1648(93)90121-2 contributor: fullname: Bellow |
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| SubjectTerms | Applied sciences Composites Exact sciences and technology Forming Forms of application and semi-finished materials Friction Friction, wear, lubrication Fundamental areas of phenomenology (including applications) Inelasticity (thermoplasticity, viscoplasticity...) Machine components Mechanical engineering. Machine design Metals. Metallurgy Physics Polymer composites Polymer industry, paints, wood Press forming of metal foils and wires Production techniques Rapid tooling Sheet metal forming Solid mechanics Structural and continuum mechanics Technology of polymers Wear |
| Title | Analysis of the tribological behaviour of polymer composite tool materials for sheet metal forming |
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