Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

Chengliang Hu; Shogo Osaki; Baixuan Cai; Mitsuru Aoyama; Kuniaki Dohda

doi:10.1007/s40544-022-0717-3

Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

Chengliang Hu^*, Shogo Osaki, Baixuan Cai, Mitsuru Aoyama, Kuniaki Dohda

^*Corresponding author for this work

Mechanical Engineering

Research output: Contribution to journal › Article › peer-review

2 Scopus citations

Abstract

This study evaluated dry-in-place lubricants used for cold forging. A group of isothermal compression tests with a strain rate (ε˙ ) range of 0.001–1 s⁻¹ and temperature (T) range of 30–400 °C were completed. The flow stress (σ) curves of annealed steel S45C were obtained, and a corresponding Hensel—Spittel model was developed to support finite element (FE) simulation. The sensitivity of the steady combined forward and backward extrusion (SCFBE) test proposed in another study was improved by approximately 20% after it was optimized using the results of the FE simulations. Key parameters were identified, and the calibration curves after optimization were obtained. On the basis of the optimized test, a friction testing setup with a heating system was developed, in which the die temperature could be adjusted from room temperature (RT) to 230 °C. Three dry-in-place lubricants and conventional phosphating lubricant were tested, and the friction factors (m), forming loads, and ejection loads were measured. The surface features of the specimens after testing were also investigated. According to the testing results, of the three tested dry-in-place lubricants, the mica type was the best. In addition, the optimized friction testing design was verified as effective. [Figure not available: see fulltext.].

Original language	English (US)
Pages (from-to)	1862-1876
Number of pages	15
Journal	Friction
Volume	11
Issue number	10
DOIs	https://doi.org/10.1007/s40544-022-0717-3
State	Published - Oct 2023

Funding

This research was partially supported by the National Natural Science Foundation of China (NSFC; No. 51875348). Chengliang HU. He is currently a professor in Institute of Forming Technology & Equipment, School of Materials Science and Engineering, Shanghai Jiao Tong University, China. He is part of the National Engineering Research Center of Die and Mold Computer Aided Design (CAD). He has more than 10 years’ research experience working in areas of precision forging processing technologies and tribology in metal forming. As the leader, he has managed 20 research projects sponsored by National Natural Science Foundation of China, Ministry of Industry and Information Technology (MIIT) of the People’s Republic of China, and industrial companies.

Keywords

cold forging
forming load
friction factor (m)
lubrication
optimization
sensitivity

ASJC Scopus subject areas

Mechanical Engineering
Surfaces, Coatings and Films

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10.1007/s40544-022-0717-3

Cite this

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title = "Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method",

abstract = "This study evaluated dry-in-place lubricants used for cold forging. A group of isothermal compression tests with a strain rate (ε˙ ) range of 0.001–1 s−1 and temperature (T) range of 30–400 °C were completed. The flow stress (σ) curves of annealed steel S45C were obtained, and a corresponding Hensel—Spittel model was developed to support finite element (FE) simulation. The sensitivity of the steady combined forward and backward extrusion (SCFBE) test proposed in another study was improved by approximately 20\% after it was optimized using the results of the FE simulations. Key parameters were identified, and the calibration curves after optimization were obtained. On the basis of the optimized test, a friction testing setup with a heating system was developed, in which the die temperature could be adjusted from room temperature (RT) to 230 °C. Three dry-in-place lubricants and conventional phosphating lubricant were tested, and the friction factors (m), forming loads, and ejection loads were measured. The surface features of the specimens after testing were also investigated. According to the testing results, of the three tested dry-in-place lubricants, the mica type was the best. In addition, the optimized friction testing design was verified as effective. [Figure not available: see fulltext.].",

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author = "Chengliang Hu and Shogo Osaki and Baixuan Cai and Mitsuru Aoyama and Kuniaki Dohda",

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AU - Dohda, Kuniaki

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AB - This study evaluated dry-in-place lubricants used for cold forging. A group of isothermal compression tests with a strain rate (ε˙ ) range of 0.001–1 s−1 and temperature (T) range of 30–400 °C were completed. The flow stress (σ) curves of annealed steel S45C were obtained, and a corresponding Hensel—Spittel model was developed to support finite element (FE) simulation. The sensitivity of the steady combined forward and backward extrusion (SCFBE) test proposed in another study was improved by approximately 20% after it was optimized using the results of the FE simulations. Key parameters were identified, and the calibration curves after optimization were obtained. On the basis of the optimized test, a friction testing setup with a heating system was developed, in which the die temperature could be adjusted from room temperature (RT) to 230 °C. Three dry-in-place lubricants and conventional phosphating lubricant were tested, and the friction factors (m), forming loads, and ejection loads were measured. The surface features of the specimens after testing were also investigated. According to the testing results, of the three tested dry-in-place lubricants, the mica type was the best. In addition, the optimized friction testing design was verified as effective. [Figure not available: see fulltext.].

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Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

Abstract

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