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Research Papers: FORMING

Evaluation of Lubricants for Stamping of Al 5182-O Aluminum Sheet Using Cup Drawing Test

[+] Author and Article Information
Long Ju

School of Mechanical Engineering,
University of Science and Technology Beijing,
30 Xueyuan Road,
Haidian, Beijing 100083, China
e-mail: ivanbj88@gmail.com

Tingting Mao

Center for Precision Forming,
The Ohio State University,
339 Baker Systems,
1971 Neil Avenue,
Columbus, OH 43210
e-mail: mao.64@osu.edu

Julio Malpica

Honda Engineering of North America, Inc.,
24000 Honda Parkway,
Marysville, OH 43040
e-mail: Julio_Malpica@ega.honda.com

Taylan Altan

Center for Precision Forming,
The Ohio State University,
339 Baker Systems,
1971 Neil Avenue,
Columbus, OH 43210
e-mail: altan.1@osu.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 14, 2015; final manuscript received May 19, 2015; published online September 4, 2015. Assoc. Editor: Blair E. Carlson.

J. Manuf. Sci. Eng 137(5), 051010 (Sep 04, 2015) (8 pages) Paper No: MANU-15-1035; doi: 10.1115/1.4030750 History: Received January 14, 2015

Lubricants are necessary to avoid adhesion, galling, and scratching in aluminum stamping processes. In this study, various lubricants, including dry lubes and wet lubes, were evaluated using cup drawing test (CDT) for stamping of Al 5182-O aluminum sheets. The effects of surface texturing, with electro-discharge texturing (EDT) and mill finish (MF), on the friction behavior were also investigated. Furthermore, the methodology to evaluate the performance of lubricants was established based on (a) maximum applicable blank holder force (BHF) and (b) draw-in length in flange or flange perimeter of formed cups. Finite element (FE) simulations were carried out to determine the coefficient of friction (CoF) at tool–workpiece interface during deep drawing under different lubrication conditions. Flow stress data of Al 5182-O material were obtained using viscous pressure bulge (VPB) and tensile tests. In this study, it was confirmed that, in forming Al 5182-O, dry film lubricants have better lubricity than wet lubricants. A better lubrication condition was found with EDT surface texture.

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Figures

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Fig. 1

Flow stress curves obtained from tensile test and VPB test

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Fig. 2

3D measurements of surface texture (Al 5182-O, 1.5 mm): (a) EDT and (b) MF, provided by Honda Engineering

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Fig. 3

Schematic of the cup drawing operation (CDT) and tooling

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Fig. 4

Deep draw tooling used in CDT [7]

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Fig. 5

Test procedure for the evaluation of lubricants

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Fig. 6

Flange perimeter recorded for 13 lubricant tests at 16 ton BHF (B, D, H, and N failed at 16 ton BHF). Note: The y-axis on the graph does not start from 0. The error bands show the deviation between samples.

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Fig. 7

Flange perimeter recorded for five lubricant tests at 17 ton BHF (A, C, E, I, and J failed at 17 ton BHF). Note: The y-axis on the graph does not start from 0. The error bands show the deviation between samples.

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Fig. 8

Comparison between MF and EDT at (a) 16 ton BHF and (b) 17 ton BHF

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Fig. 9

Comparison of flange perimeters obtained from simulation and experiment to predict the CoF at 16 ton BHF for Al 5182O/MF

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Fig. 10

Comparison of flange perimeters obtained from simulation and experiment to predict the CoF at 17 ton BHF for Al 5182O/MF

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Fig. 11

Thickness comparison between experiment and simulation of drawn cup with lubricant F: (a) rolling direction and (b) transverse direction

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Fig. 12

Thickness comparison between experiment and simulation drawn cup with lubricant I: (a) rolling direction and (b) transverse direction

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