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TECHNICAL PAPERS

Thermal Effects on Polymer Laminated Steel Formability in Ironing

[+] Author and Article Information
Chen-Hsi Huang, Steven R. Schmid

Department of Aerospace and Mechanical Engineering, University of Notre Dame, Notre Dame, IN 46556

Jyhwen E. Wang

Weirton Steel Corporation, 3006 Birch Drive, Weirton, WV 26062

J. Manuf. Sci. Eng 123(2), 225-230 (Mar 01, 2000) (6 pages) doi:10.1115/1.1346688 History: Received June 01, 1999; Revised March 01, 2000
Copyright © 2001 by ASME
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References

Hosford,  W. F., and Duncan,  J. L., 1994, “The Aluminum Beverage Can,” Sci. Am., 271, pp. 48–53.
Gibson, J., 1983, Tribology in Metalworking: Friction, Lubrication, and Wear, American Society for Metals, New York.
Mear, R., and Topper, H., 1963, “Plastics as Lubricants for Deep Drawing and Press Work,” Sheet Metal Ind., pp. 567–570.
Schey, John A., 1984, Tribology in Metalworking: Friction, Lubrication, and Wear, Metals Park, American Society for Metals.
Jaworski,  J. A., Schmid,  S. R., and Wang,  J. E., 1999, “An Experimental Investigation of the Survivability and Friction Characteristics of Tin-Coated and Polymer-Laminated Steels,” J. Manuf. Sci. Eng., 12, pp. 232–237.
Jaworski, J. A., 1997, Tribology and Formability Characteristics of Polymer-Laminated Steels, Master’s Thesis, University of Notre Dame.
Kalpakjian, S., and Schmid. S. R., 2000, Manufacturing Engineering and Technology, 4th Ed., Prentice Hall, Englewood Cliffs, NJ.
Dohda,  K., and Kawai,  N., 1990, “Compatability Between Tool Materials and Workpiece in Sheet-Metal Ironing Process,” J. Tribology, 112, pp. 275–280.
Jaworski,  J. A., and Schmid,  S.R., 1999, “Survivability of Laminated Polymer Lubricant Films in Ironing,” Tribol. Trans., 42, pp. 32–38.
Azarkhin,  A., and Richmond,  O., 1992, “A Model of Ploughing by a Pyramidal Indentor - Upper Bound Method for Stress-Free Surfaces,” Wear, 157, pp. 409–418.
Wilson,  W. R. D., and Halliday,  K., 1977, “An Inlet Zone Analysis for the Lubrication of a Drawing Process by a Rigid-Plastic Solid,” Wear, 42, pp. 135–148.
Hosford, W. F., and Caddell, R.-M., 1993, Metal Forming: Mechanics and Metallurgy, Prentice-Hall, Englewood Cliffs, NJ, pp. 146–167.
Drucker,  D.C., Prager,  W., and Greenberg,  H. J., 1952, “Extended Limit Theorems for Continuous Media,” Q. J. Mech. Appl. Math., 9, pp. 381–389.

Figures

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Schematic illusltration of the polymer lamination process
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Critical tooling temperature vs. die angle. Parameters are as follows: white polyester coating, yi=0.21 mm, ti=0.01 mm.
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Surface micrographs of representative surfaces: (a) chrome plated steel as received (b) polymer coating before ironing (c) polymer coating after successful ironing (d) polymer coating after unsuccessful ironing
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(a) Velocity discontinuity field for successful ironing model and (b) its corresponding hodograph
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(a) Velocity discontinuity field for shaving model and (b) its corresponding hodograph
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Power curves of successful ironing model with various reduction of thickness. Parameters are as follows: kw/kc=3.3, Θt=28 °C.
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Optimized power vs. die angle ϕ for successful ironing model and shaving model–yi=0.21 mm, ti=0.01 mm, vp=0.1 m/s, Θt=28 °C
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Thermal effects on the effective shear strength of the polymer–yi=0.21 mm, ti=0.01 mm
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Critical die angle vs. initial coating thickness for polyester coated steel with various tooling temperatures. yi=0.21 mm, vp=0.1 m/s.

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