Tribology in Metal Working

This thesis focuses on the tribological performance of tool surfaces in two steel working operations, namely wire drawing and hot rolling. In all forming operations dimensions and surface finish of the products are of utmost importance. Forming basically includes three parts – forming conditions excluded – that may be changed; work material, tool and (possibly) lubricant. In the interface between work material and tool, the conditions are very aggressive with – generally or locally – high temperatures and pressures. The surfaces will be worn in various ways and this will change the conditions in the process. Consequently, the surface finish as well as the dimensions of the formed product may change and in the end, the product will not fulfil the requirements of the customer. Therefore, research and development in regard to wear, and consequently tribology, of the forming tools is of great interest. The investigations of wire drawing dies focus on coating adhesion/cohesion, surface characteristics and material transfer onto the coated steel both in laboratory scale as well as in the wire drawing process. Results show that it in wire drawing is possible to enhance the tribological performance of drawing dies by using a lubricant together with a steel substrate coated by a polished, dual-layer coating containing both hard and friction-lowering layers. The investigations of hot rolling work rolls focus on microstructure and hardness as well as cracking- and surface characteristics in both laboratory scale and in the hot strip mill. Results show that an ideal hot work roll material should be made up of a matrix with high hardness and a large amount of complex, hard carbides evenly distributed in the microstructure. The surface failure mechanisms of work rolls are very complex involving plastic deformation, abrasive wear, adhesive wear, mechanical and thermal induced cracking, material transfer and oxidation. This knowledge may be used to develop new tools with higher wear resistance giving better performance, lower costs and lower environmental impact.

Robust surface practices for sheet metal forming dies

Examines the use of surface coatings in stamping using an overall systems approach. The effects of die coating surface properties on friction, wear and part strain, have been studied in-plant with an emphasis on optimising the tool coating system to provide robust sheet metal forming procedures.

Soil geochemical analyses as an indication of metal working at the excavation of a house in the Roman City at Silchester (UK)

Silchester is the site of a major late Iron Age and Roman town (Calleva Atrebatum), situated in northern Hampshire (England (UK)) and occupied between the late first century BC and the fifth or sixth century AD. Extensive evidence of the nature of the buildings and the plan of the town was obtained from excavations undertaken between 1890 and 1909. The purpose of this study was to use soil geochemical analyses to reinforce the archaeological evidence particularly with reference to potential metal working at the site. Soil analysis has been used previously to distinguish different functions or land use activity over a site and to aid identification and interpretation of settlement features (Entwistle et al., 2000). Samples were taken from two areas of the excavation on a 1-metre grid. Firstly from an area of some 500 square metres from contexts of late first/early second century AD date throughout the entirety of a large 'town house' (House 1) from which there was prima facie evidence of metalworking.

Compression and extrusion of metals using rotating dies

Experimental and theoretical investigations of compression and extrusion of metals with steadily or cyclically rotating dies were carried out. Reasonably simple models were produced by classical plasticity theory and analytical equations were developed to establish a theoretical basis for the associated phenomena. Analytical solutions agreed well with the experimental results.

Modelling of tooling wear in trim dies for AHSS

Using Advanced High Strength Steels (AHSS) in forming and cutting dies generates higher loads in tools. Tool wear is an issue when applying AHSS. This study investigates the effect of process parameters such as clearance, material properties and punch/die bluntness on contact pressure values and tool wear. Some desirable process parameters that minimise wear have been found.

Tool wear analysis in sheet metal stamping

This thesis advances the understanding of die wear in sheet metal stamping. It was found that transient conditions exist at the die radius, resulting in severe contact pressures that are critical to the wear behaviour. The findings challenge applicability of traditional wear tests and models for sheet metal stamping processes.

How did the crisis affect small and medium-sized enterprises? -- from a field study of the metal-working industry in Java

This paper focuses on the impact of Indonesia's economic crisis on small and medium-sized enterprises (SMEs). It shows how the performance of SMEs during the crisis varied widely even in the same industrial subsector, and found that the factors most affecting performance have been market orientation and the linkages that the SMEs have formed with the buyers of their products. Well-performing SMEs were found to have utilized putting-out linkages with wholesalers which enabled them to switch to products having better markets. On the other hand, the SMEs which had subcontracting linkages with assemblers or contracting linkages with user-factories (with the exception of SMEs having export-oriented linkages) suffered badly in the crisis because of specificity of products with little room for switching. The paper also found that exposure to debt due to borrowing for investment has been another factor affecting performance, but that enterprise size has had no linear correlation with performance.

Die design and construction; lanking, piercing, compound, progressive, trimming, flanging, forming, and cam dies.

Mode of access: Internet.

Findings on electrical steels, punch and die steels, presses and auxiliaries in metal stamping.

Mode of access: Internet.

Wear resistance of surface treated metal-working tools

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Elastic behaviour in mechanical draw presses

This thesis explores the elastic behaviour of the mechanical double action press and draw die system commonly used to draw sheet metal components in the automotive industry. High process variability in production and excessive time spent in die try-out are significant problems in automotive stamping. It has previously been suggested that the elastic behaviour of the system may contribute to these problems. However, the mechanical principles that cause the press system to affect the forming process have not been documented in detail. Due to a poor understanding of these problems in industry, the elasticity of the press and tools is currently not considered during the die design. The aim of this work was to explore the physical principles of press system elasticity and determine the extent to which it contributes to problems in try-out and production. On the basis of this analysis methods were developed for controlling or accounting for problems during the design process. The application of frictional restraining force to the edges of the blank during forming depends on the distribution and magnitude of the clamping force between the binders surfaces of the draw die. This is an important control parameter for the deep drawing process. It has been demonstrated in this work that the elasticity of the press and draw die can affect clamping force in two ways. The response of the press system, to the forces produced in the press during forming, causes the magnitude of clamping force to change during the stroke. This was demonstrated using measured data from a production press. A simple linear elastic model of the press system was developed to illustrate a definite link between the measured force variation and the elasticity of the press and tools. The simple model was extended into a finite element model of the complete press system, which was used to control a forming simulation. It was demonstrated that stiffness variation within the system could influence the final strains in a drawn part. At the conclusion of this investigation a method is proposed for assessing the sensitivity of a part to clamping force variation in the press during die design. A means of reducing variation in the press through the addition of a simple linear spring element is also discussed. The second part of the work assessed the influence of tool structure on the distribution of frictional restraining forces to the blank. A forming simulation showed that tool stiffness affects the distribution of clamping pressure between the binders. This was also shown to affect the final strains in a drawn part. However, the most significant influence on restraining force was the tendency of the blank to increase in thickness between the binders during forming. Using a finite element approximation of the try-out process it was shown that the structure of the tool would also contribute to the problems currently experienced in try-out where uneven contact pressure distributions are addressed by manually adjusting the tool surfaces. Finally a generalised approach to designing draw die structures was developed. Simple analysis methods were combined with finite element based topology optimisation techniques to develop a set of basic design guidelines. The aim of the guidelines was to produce a structure with uniform stiffness response to a pressure applied at the binder surface. The work concludes with a recommendation for introducing the methods developed in this thesis into the standard production process.

Experimental analysis of friction in forming automotive coated steels

The thesis addressed and answered a number of key issues in the experimental analysis of friction in sheet forming operations. Conventional friction theories were linked with the properties of sheet coatings and the process geometries. Newly derived mathematical models extended the analysis of friction in sheet metal forming applications.

Die-casting practice /

Includes index.

The little handbook; a buyer's guide for stampings and tank heads, with certain useful mathematical tables and formulae.

Book No. 2.

Operator, organizational, direct support, general support, and depot maintenance manual ... : crimping outfit, hydraulic, voicemitter-outlet valve assembly, ABC-M1.

"June 1968."