Effects of Rolling Direction and Lubricant on Friction in Sheet Metal Forming

Abstract

Lubrication and friction at workpiece-tool interface play an important role in product quality control of sheet metal forming process. Surface microstructures of sheets have a great influence on the development of lubrication films. In order to investigate the effects of the rolling direction of aluminum alloy sheet and lubricant on the friction behavior in sheet metal forming, strip drawing test was used. The sample used was electric discharge texturing (EDT) surface. Lubricants, both with and without additives, were used. The strip drawing tests were performed at angles between the sliding and rolling directions of 0–90 deg. Variations in the sheet surface topography were analyzed by comparing the sheet surface microstructures and its 3D surface parameters before and after the strip drawing test. Results of the strip drawing tests indicate that the kind and amount of lubricant have great influences on friction at the interface, and the lubricant with additives benefits improving the friction behavior between the sheet and the tool. The EDT surface of the aluminum alloy sheet has an anisotropic frictional property during deep drawing process due to different angles between the sliding and rolling directions. When the sliding direction is parallel to the rolling direction, the coefficient of friction has the highest value. When the angle between the sliding and rolling directions increases, the coefficient of friction decreases. The surface microstructure of the sheets after the strip drawing test at different angles between the sliding and rolling directions has been modified, and its 3D surface parameters decrease significantly to a different degree.