Friction and Lubrication

October 15th, 2014

Hyunok Kim, EWI Forming Center

Taylan Altan, OSU - Center for Precision Forming (CPF)

1
Introduction

Tribology is the science of friction, lubrication and wear.

Friction is a resistance to sliding between two bodies in
contact under a normal load.
Lubrication is the process, or technique used to reduce
wear of one or both surfaces in close contact, and moving
relative to each other.
Wear is damage to a solid surface, involving loss or
displacement of material.

2
Friction Law

Coulomb law are commonly used for sheet metal forming.

N

= =

F
F = Frictional force
N = Normal force
Area (A)
= Frictional shear stress
= Normal stress

3
Stribeck curve showing onset
of various lubrication
mechanisms = lubricant viscosity;
v = sliding velocity;
p = normal pressure;
= coefficient of friction.

4
Various Lubrication Mechanism

a) Thick Film
(not realistic for
stamping)

b) Thin Film
(rarely seen in
stamping)
(Sources: Pax Products, Inc.)

c) Mixed Lubrication: Well lubricated

interface in stamping (=0.01 ~ 0.1)

d) Boundary Lubrication: pre-

lubricated interface in stamping
(=0.1 ~ 0.2)

5
Factors Influencing Friction and
Lubrication

6
Evolution of Tool Wear (Galling)

Surface roughness/ Hardness of

Contact pressure/ coatings/ Lubricant behavior
Interface temp./ Atomic bonding force/
Forming speed Chemical interactions

7
Lubrication process with oil-
based (wet) lubricant
Three important factors such as Cost, Performance
and Compatibility (with different materials and post-
processes) should be considered to select stamping
lubricants.
Additional Degreasing
Pre-Oiling Oiling (optional)
Decoiling and (optional) (optional)
cutting

Stacking
Deep Drawing +
Blanks
subsequent
(dry or
blanking
pre-oiled)
operations

[Courtesy: M. Pfestorf, 2005, BMW ]

8
Lubrication Process with Dry-
Film Lubricants

Deep Drawing +
Decoiling / Recoiling Decoiling subsequent blanking
with Lube coating by and cutting Stacking operations
immersion or spraying Blanks

Hot bath

[Courtesy: M. Pfestorf, 2005, BMW ]

9
Various Tests for Evaluating
Stamping Lubricants

10
Evaluation of Lubricants
Strip Drawing Test
In this test a strip is drawn between two opposing flat dies that are wider
than the strip. The coefficient of friction is given by
=F/2P

The coefficient of friction may be changed with the amount of stretching.

The test can be performed in different speeds or speed profile, different
radii and die material.

Strip drawing test Courtesy: United State Steel Corp.

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Stamping (Draw Bead) Test

Pressure
Pull hydraulic Force
gauge
cylinder transducer
BHF
hydraulic
cylinder

Die location

Jaws

Courtesy: Lubrizol Metalworking Additives

12
Influence of Draw Beads

[Courtesy: J. Reid, 2005 Lubrication Workshop in OSU]

13
 Stamping (Draw Bead) Test
Binder holder force Binder holder force
Pulling force (BHF) (BHF)
(measured)

The general procedure in this test involves pulling a lubricated sheet

specimen through the drawbead dies and measuring the forces needed to
pull the sheet.
BHF and pulling velocity can be changed to emulate field conditions.
For different lubricants coated on the specimen, the frictional forces and
pulling forces are different.
An SLT number, which quantifies lubricant performance, is calculated relative
to a reference lubricant.

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Twist Compression Test

Twist Compression Test (TCT) is widely used as a laboratory screening

test for evaluating metal working lubricants
In the TCT, a rotating annual tool is pressed against a fixed sheet metal
specimen with selected pressure and sliding speed to simulate the metal
forming process.
The coefficient of friction (COF, ) is estimated as a function of time by the
ratio of friction force and normal force.

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TCT for Evaluation of Galling

r = 12.7 mm

Tool
surface
Galling

Galling 0 Galling 3

16
Cup Drawing Test (CDT)

12 inch Initial
blank

6 inch

Deep
drawn cup

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 Principle of CDT
As blank holder pressure (Pb) increases, frictional stress ()
increases based on Coulombs law.

Schematic of deep drawing Evaluation criteria:

Pb
Coulombs law
where = the frictional shear stress
the coefficient of friction
Pb = the blank holder pressure
18
Max. punch force
Max. BHF w/o fracture
Flange draw-in length
Flange perimeter
Test Results of Cup Drawing

Click a web link () to watch the video of testing video.

19
Effects of Deformation Heat on
Lubricants

Simulation parameters
Punch diameter = 152.4 mm
Sheet diameter = 304.8 mm
Punch velocity = 70 mm/sec
BHF = 300 KN

(Sheet material : DP590 and

Thickness=1.24 mm)
[FEM Code: DEFORM-2D]

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Test Results of Cup Drawing

Shorter Better
perimeter lubricant

21
 Strip Drawing Test (SDT)

The strip drawing test (SDT) was developed to test the higher grades of AHSS
(DP780, TRIP780 and DP980), because the limited formability of these steels
makes the deep drawing test difficult to conduct.

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 Strip Drawing Test
Dimensions of strip:
Length = 356 mm
Width = 25 mm

With preliminary FE simulations of SDT, four different die radii of 5, 8, 10 and 12

mm were determined to change the contact pressure in the range of 110 ~ 260
MPa without any necking of strip.

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 SDT for Evaluating Lubricants
with AHSS
Testing parameters Descriptions

Sheet materials DP590 GA (thickness=1.2 mm) and DP600 GI (thickness=1.0 mm)

Die surface DC53 uncoated (Ra=0.19 m and 830 VHN)

conditions DC53 PVD coating of TiCN (Ra=0.34 m and 2500 VHN)

Die corner radius 8 mm

Blank holder force 40 KN for DP600 GI and 50 KN for DP590 GA

Lub B: Polymer-based lubricant with EP additives

Lubes C and D: Water-soluble dry film lubricants

Lubes E and L: Water-free dry film lubricants

Lubricants
Lub M: Synthetic lubricant

Lub N: Straight oil

Lub S: Water-soluble lubricant

24
SDT for Evaluating Lubricants
with AHSS

25
SDT for Evaluating Lubricants
with AHSS

26
Summary of Lubrication and
Friction
Good lubrication is crucial to form the part
successfully.
Friction at sheet-die interface is affected by the
lubricant, die material and coating, surface finish of
the sheet and die, and process conditions
(temperature, forming speed and contact pressure)
There are several methods to evaluate the
performance of lubricants.
Cup draw and strip draw tests are most practical and
they emulate the lubrication conditions existing in
production.

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Questions & Contacts
Taylan Altan Hyunok Kim
614.292.5063 614.688.5239
altan.1@osu.edu hkim@ewi.org