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Reduction in Friction in Ironing of
Aluminium Alloy and Stainless Steel Drawn Cups
Name : Witthaya Daodon
Nationality : Thailand
Educational background
Year Institution Qualification
1998-2000Rajamangala University of Technology
Diploma of Machine Tools Technology
2000-2003King Mongkut’s University of Technology Thonburi
Bachelor of Engineering
2009-2012King Mongkut’s University of Technology Thonburi
Master of Engineering
Working experiences
Year Company Position
2003-2004 Thai Ahresty Die Co., Ltd. CAD/CAM engineer
2004-2005Honda Automobile (Thailand) Co., Ltd.
Machining staff
2006-2008 Siam Lemmerz Co., Ltd. Design engineer
2008-2009 Sunway E-Systems (Thailand) Ltd.
Application engineer1
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
2
Electric vehicles
Battery weight,
20-25%wt of car
Battery case
Battery pack for electric car
Stainless steel
Aluminium alloy
Environmental protection
Electric, hybrid, plug-in hybrid
vehicles
Reduction of CO2emission
Key component,
Battery
Weight Efficiency
3
Blank
Cup
(a) Multi-stage stamping
(b) Impact extrusion
Battery case production processes
Redrawing
Deep drawing
die
Punch
Blank holder
Deep drawing
Ironing die
Ironing
High contact pressure
Large deformation,Long sliding
Punch
Billet
Die
Seizure
Stainless steel
High strength
Low thermal
conductivity
Aluminium alloy
High adhesion
Low friction tool
materials
Lubrication
Coating
Reduction in friction
4
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
5
Ironing of stainless steel and aluminium alloy
drawn cup using TiCN-based cermet die
A TiCN-based cermet die was utilised to improve the limit in ironing of
stainless steel and aluminium alloy drawn cups.
1mm
SeizureIroning dieH
ard
ness /
HV
Coefficient of friction
Tool steel DIN 1.2379(JIS SKD11)
CrN
TiC
TiCN
TiN
CVD-coatingsPVD-coatings
WC/C
MoS2
3000
2000
1000
4000
0.6 0.80.40.200
SeizureIroned cup
Tool steel
Hardness: low
Friction: high
Seizure resistance: low
TiCN-based cermet
Hardness: high, Friction: low
Seizure resistance: high
6
Ironing conditions and die materials
Die materials Young’s modulus [GPa] Vickers hardness [HV]
Tool steel SKD11 206 750
Non-coated WC-Co 610 1650
TiC-coated WC-Co 610 1650, 3000(TiC)
TiCN-based cermet 410 1550
1mm
(a)Tool steel
Circumferential
Axia
l
RingDie Sintering
Lubricant
Drawn cup;
SUS304,
SUS430
A3003-O
dp
Punch
c
f 34
Die
v=100mm/s
Ring
7
Ironing load-stroke curve for SUS304
with different tool materials, dp=33.16 mm
10
20
30
40
50
60
0 10 20 30
70
Stroke [mm]40
80
90Non-coated WC-Co, r=16%
TiC-coated WC-Co, r=14%
8
Ironing limit, surface of die land and ironed cups
for stainless steels with different tool materials
0
10
20
Ironin
g r
atio r
[%]
Fracture
No defectSeizure
Seizure and fracture
No seizure1mmSeizure
Non-coated WC-Co
10mm 0.5mm
Die
0
10
20
25
Ironin
g r
atio r
[%]
1mm
No defect
Seizure
(a) SUS304 (b) SUS430 9
Ironing limit for A3003 cup with different tool materials
1mm
0
10
20
30
40
No defect
Seizure
Ironin
g r
atio r
/%
Seizure
Tool steel Non-coated WC-Co
TiC-Coated WC-Co
Seizure and fracture in edge
Fracture in edgePortion of observation
Ironing die
10
Before ironing
Tool steel
30.8
30.3
TiC-coated WC-Co
32.9
32.1
(a) Ironed SUS304 cups
Young’s modulus: largeExpansion: small
Height: tall
Reduction in thickness: large
Thin wall
Young’s modulus: smallExpansion: large
Height: short
Reduction in thickness: small
Thick wall
Expansion of die
Die
Punch
Ring
Clearance
(b) Expansion of die 11
Effect of Young’s modulus of die
on height and sidewall thickness of ironed cup
Su
rfa
ce
ro
ugh
ne
ss [
mm
Ra]
Number of strikes n
Blank
0
0.02
0.04
0.06
0.08
0.10
0.12
20 40 60 80 100
SUS430,TiC-coated WC-Co
A3003,TiC-coated WC-Co
SeizureTiC-coated WC-Co
Punch
Deep drawing
die
Ring
Ironing die
Ironed cup and variation of surface roughness
of ironed cups in repeated ironing
Repeated ironing
12
Conclusions
The limits in ironing of stainless steel and aluminiumalloy drawn cups were effectively improved by using theTiCN-based cermet die.
The height of ironed stainless steel cups with the TiC-coated WC-Co die was the highest and followed by theTiCN-based cermet die.
For repeated ironing of the ferritic stainless steelSUS430 and aluminium alloy A3003 cups using theTiCN-based cermet die, the cups were successfullyformed up to 100 and 50 strokes.
1.
2.
3.
13
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
14
Die having lubricant pockets
(a) Polished
Polished surface
Cup Die
Lubricant
Cup
Die
The TiCN-based cermet die having fine lubricant pockets was utilised to
reduce friction in ironing of stainless steel and aluminium alloy drawn cups.
(b) Die having lubricant pockets
Ironed cups
Reduction in friction in ironing of stainless steel and
aluminium alloy drawn cup using die having lubricant pockets
Punch
Ironing
die
Cup
Liquid lubricant
15
Ironing conditions
Material: TiCN-based cermet
Surface:
• Polished (0.02μmRa)
• Surface having lubricant pockets
(0.03~0.21μmRa)
• Shot-peened (0.05~0.34μmRa)
Ironing dieLubricant
Drawn cup;
SUS304,
SUS430,
A3003-O
dp
Punch
c
f 34
Die
Ironing speed;
v=100mm/s
Ring
Sheet Tensile strength [MPa] Elongation [%] n-value r-value
SUS304 710 59.3 0.40 1.01
SUS430 547 25.7 0.20 1.17
A3003 106 26.8 0.21 0.42
16
0.05µmRa, 0.02µmRpk, 0.18µmRvk
0.17µmRa, 0.19µmRpk, 0.14µmRvk
(b) Shot-peened
-2
0
Position in axial direction /µmH
eig
ht
/µm 1
-1
0 200 400100 3000.1mm
(a) Polished, 0.02µmRa, 0.01µmRpk, 0.06µmRvk
(c) Surface having lubricant pockets
0.12µmRa, 0.02µmRpk, 0.23µmRvk
0.06µmRa, 0.01µmRpk, 0.43µmRvk
Surface shapes of die land
17
Effect of die land surface on ironing limit for SUS430 cup
(a) Shot-peened (b) Die having lubricant pockets
Iro
nin
g r
atio
r/%
30
20
10
00.40.2 0.30.1
25
15
5
35
Reduced valley depth in land portion of die /µmRvk0.5
Seizure
Fracture
No defect
Seizure
0.4
0
0.1
0.3
0.2
Re
du
ce
d p
ea
k h
eig
ht in
la
nd
p
ort
ion
of d
ie /µ
mR
pk
Po
lish
ed
Rpk
Ironing die
0.1mm
Fracture Seizure
0.2mm
Large pockets
Flat portion
18
Ironing limit for die having lubricant pockets and
A3003 cups
Iro
nin
g r
atio
r/% 30
20
10
00.40.2 0.30.1
25
15
5
35
0.5
0.4
0
0.1
0.3
0.2
Polished
40
45
Fracture
Seizure
10mm
0.5
No defect
Re
du
ce
d p
ea
k h
eig
ht in
la
nd
po
rtio
n o
f d
ie
/µm
Rp
k
Reduced valley depth in land portion of die /µmRvk
Rpk
19
Relationship between average ironing load and
ironing ratio for SUS430 cups
30
20
10
40
10 15 20 25 305
Ave
rag
e iro
nin
g lo
ad
/kN
Polished (0.02µmRa)
Die having lubricant pockets,
0.03µmRa~0.15µmRa
0
Shot-peened,
0.06µmRa~0.14µmRa
Ironing ratio r /%
20
Conclusions
1. The ironing limit with the die having lubricant pockets forthe reduced valley depth of 0.22 µm to 0.42 µm wasimproved.
2. The reduced peak height was more than 0.06 µm, thedefect early occurred at a low ironing ratio.
3. The average ironing load of SUS430 cup with the diehaving lubricant pockets was reduced about 20%compared to the polished die.
21
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
22
Die having lubricant pockets
The conditions of the ironing process and lubrication for attaining low friction
in ironing of stainless steel cups using the cermet die having fine lubricant
pockets were investigated.
Lubrication behaviours in ironing of stainless steel cup
with die having lubricant pockets
During ironing
Enhanced lubrication
Measurement of thickness of remaining lubricant
DieLamp
Camera
l
t
Glass Fluorescence oil-mixed lubricant
Steel ball
Die
Ultraviolet rayslamp
Camera
PunchRemaininglubricant
State of lubrication,Conditions for reducing friction
Ultraviolet rays lampLubricant
+Fluorescence oil, 1wt%
23
Cup
Die
Distribution of thickness of remaining lubricant on
sidewall of ironed cup for v=100 mm/s
zDistance from bottom of ironed cup z /mm
0
5
10
15
20
5 10 15 20 25
25
30
Thic
kness o
f re
main
ing lubricant
/μm
Corner Sidewall
30
Polished, Chlorine, r=12.8%
Reflection of ultraviolet lights
10mm
Measuring position
Die having lubricant pockets, Sulfur, r=5.7%
Polished, Sulfur, r=5.5%
Die having lubricant pockets, Chlorine, r=13.7%
24
Effect of extreme-pressure additives on ironing limit
for v=100mm/s
10mm
Iro
nin
g r
atio
r/%
(b) Chlorine
0
20
10
30
No defect
Fracture
0.1mm
Seizure
(a) Sulfur
0
20
10
Iro
nin
g r
atio
r/% Seizure
0.1mm
No defect
Portion of observation
Ironing die
25
Effect of ironing speed on ironing limit and thickness
of remaining lubricant on sidewall of ironed cup
with lubricant containing chlorine additive
Iro
nin
g r
atio
r /%
(i) Die having lubricant
pockets
0100 15050
20
10
30
Ironing speed v /mm·s-1
No defect
Fracture
(ii) Polished
0 50 100 150
No defect
Seizure
(a) Ironing limit
Polished, r=13%
Die having lubricant pockets,
r=25%
Th
ickn
ess o
f re
ma
inin
g
lub
rica
nt /μ
m
Ironing speed v /mm·s-1
4
050 100 150
2
1
3
5
6
b) Thickness of remaining lubricant on sidewall of ironed cup 26
Cup
Die
0.1mm
No seizure
Ave
rag
e iro
nin
g lo
ad
/kN
Amount of applied lubricant /µg·mm-2
30
0
10
20
40
37030 4515
Die having lubricant pockets
Seizure
Polished
Th
ickn
ess o
f re
ma
inin
g
lub
rica
nt /μ
m
Die having lubricant pockets
Polished
3
0
1
2
37030 4515
Seizure
Effect of amount of applied lubricant on seizure limit
and thickness of remaining lubricant with lubricant
containing chlorine additive for v=100mm/s and r=13%
(a) Seizure limit b) Thickness of remaining lubricant on sidewall of ironed cup 27
Su
rfa
ce
ro
ug
hn
ess o
f iro
ne
d
cu
p /μ
mR
a
0.1mm
Number of strikes n
0
0.50
0.20
0.10
0.40
0.30
Severe seizure
Mild seizure
Mild seizure
15050 100 250200 300
Blank
Polished
Die having lubricant pockets
25
(a) Die having lubricant pocketsn=10 n=300
(b) Polished
Fracture
Seizure
0.1mm
n=10 n=150
10mm
Ironed cup and variation of surface roughness
of ironed cups in repeated ironing
Punch
Deepdrawing
Ironing
Repeated ironing
28
Conclusions
1. For the die having lubricant pockets, the sufficientamount of the lubricant and the high ironing speed werethe better condition for reducing friction.
2. The film thickness of the remaining lubricant with the diehaving lubricant pockets was thicker than that with thepolished die.
3. In repeated ironing, the surface roughness of ironedcups maintained the same level regardless of thenumber of strikes for the die having lubricant pockets.
29
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
30
b) Die havinglubricant pockets
c) Rougheningsurface of cup
Trapped lubricant
Large trapped lubricant
IroningSqueezed
out lubricantDuring ironing
Die
Lubricant
Cup
Before
a) Polished die Axial CircumferentialFineRough
d) Sanding
Rough
e) Deep drawingwith large clearance
Large clearance
Small radius
f) Two-stage deepdrawing
Improvement of lubrication in ironing of
stainless steel cup by surface roughening
Surface roughening of drawn cups was utilised to improve lubrication in
ironing of stainless steel cup. 31
Effect of sanding direction of cup on ironing load-stroke
curve for lubricant containing sulphur additive
Axial sanding with #80,Rz=0.35µmRa, r =11.4%
20
40
Stroke /mm
Iro
nin
g lo
ad
/kN
0 5 10 15 20 25 30
10
30
50
Circumferential sanding with #80,Rz=0.60µmRa, r =12.1%
32
Lubricant squeezed out
Lubricant trapped
(a) Axial sanding
(b) Circumferential
sanding
Effect of arithmetic mean surface roughness of cup on
ironing limit for lubricant containing sulphur additive
Surface roughness of cup in axial direction Rz /μmRa
Iro
nin
g r
atio
r /%
0.60.40.2 0.3 0.50.1
30
20
10
0
Seizure
No defect
Drawn cup with chorine additives
(a) Polished (0.02μmRa)
0.1mm
Circumferential
sanding with #1500
Circumferential
sanding with #80Drawn cup
0 0.40.2 0.3 0.50.1 0.6
No defectSeizure
(b) Die having fine lubricant pockets
(0.06μmRa)
Drawn cup with chorine additives
Axial sanding with #80
33
Ironing limit for cups formed by deep drawing with
large clearance and two-stage deep drawing
cd=100%, chlorine additives
No defect
30
20
10
Seizure andfracture
Iro
nin
g r
atio
r/%
Seizure
Seizure
0.1mm
cd=100%, sulphur additives
Deep drawing with large clearance,
cd=120%, Rz=0.43μmRa
Two-stage deep drawing including
deep drawing and redrawing with
small die radius, Rz=0.57μmRa
Large clearance
Small radius
34
Relationship between coefficient of friction in ironing
and ironing ratio
10 15 20 255
Ironing ratio r /%
0.16
0.12
0.08
0.04
0
Co
effic
ien
t o
f fr
ictio
n
Circumferential sanding with #80, Rz=0.60μmRa
Drawn cup, Rz=0.30μmRaDeep drawing with large clearance, cd =120%, Rz=0.43μmRaRedrawn cup, Rz=0.57μmRa
35
Effect of surface roughness of drawn cup on
average thickness of remaining lubricant
0.3 0.40.20.1 0.50 0.6 0.7
0.5
1.0
1.5
2.0
Surface roughness in axial direction of cup Rz /μmRa
Ave
rag
e th
ickn
ess o
f lu
bri
ca
nt film
in
sid
ew
all
fro
m 1
5m
m to
30
mm
/μ
m
Drawn cup,0.30μmRa
Deep drawing with large clearance, cd=120%,
0.43μmRa
Circumferentialsanding with#80, 0.60μmRa
Redrawing,0.57μmRa Cup
Die
Enhanced lubrication
15~30
36
Conclusions
1. The ironing limit with the cup sanded in thecircumferential direction was higher than with the cupsanded in the axial direction.
2. Friction in ironing was reduced by roughening of cupsurface because of the improvement of lubrication.
3. The thickness of the remaining lubricant on the sidewallof the ironed cup increased as the surface roughness inthe axial direction of the drawn cup increased.
37
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
38
Lubricant containing fine particles for improving
seizure resistance in ironing of aluminium alloy cup
The lubricant containing fine particles was applied to improve
the seizure resistance in ironing of aluminium alloy cups.
Fine SiO2 particles,
0.01µm
Metal cutting,
sliding bearing
Lubricant
SiO2particle
Cup
Die
Seizure
(a) Lubricant without particles
(b) Lubricant with particles
Machining process
Tool
Workpiece
Fine SiO2particles
Prevention of contact
Cutting oil
Aluminium alloy,
high adhesion
39
Ironing conditions by lubricant containing fine particles
Drawn cup;
A3003-Odp
Punch
c
f 34
100mm/s
Ring
Lubricant+fine particles
W=0~5wt%(0~2vol%)
Die,Polished
Particles Hardness /HV Density /g·cm-3Average particle size ds/nm
SiO2 950 2.2 10, 300 and 500
ZrO2 1230 5.68 13
Al2O3 1570 3.95 15
Material properties of fine particles
Lubricant
Paraffin oil,
Kinematic viscosity
v= 10 and 500 mm2/s
A3003-O: 31 HV, TiCN-based cermet: 1550 HV
40
Effect of types of fine particles mixed in lubricant on
seizure resistance for ν=10 mm2/s, W=1wt%
Fine particles
SiO2 ZrO2
Ironing limit of lubricant without particlesIr
on
ing
ra
tio
r /%
0
20
10
30
40
Al2O3
No defect
Seizure
0.1mm
Seizure
41
Effect of size of fine SiO2 particles mixed in
lubricant on ironing limit and average ironing load
for ν=10 mm2/s and W=5wt%
(a) Ironing limit and surface of die land (b) Average ironing load
for r=23%
Size of particles ds [µm]A
ve
rag
e iro
nin
g lo
ad
[kN
]
0.0
1µ
m
0
4
2
6
0.5
µm
0.3
µm
With
ou
t p
art
icle
Size of particles ds [µm]0.1 0.40.2 0.3
Ironing limit of lubricant without particles
Iro
nin
g r
atio
r [%
]
0
20
10
30
0.1mm
40
0.5
No defect
No defect
Portion of observation
Ring
Ironing die
Seizure and fracture
Seizure
42
Effect of quantity of fine SiO2 particles mixed in
lubricants on ironing limit for ds=0.01μm
Mixing quantity of SiO2 W [wt%]1 2 301 542 3
Ironing limit of lubricant without particles
(a) ν =10 mm2/s (b) ν =500 mm2/s
No defect
Seizure
Ironing limit of lubricant without particles
Iro
nin
g r
atio
r [%
]
0
20
10
30
40
No defect
Seizure and fracture
Seizure
Portion of observation
Ironing die0.1mm
No defect
0.1mm
Seizure
43
SEM observation and quantification of Si element on
sidewall of ironed cup
ν =10 mm2/s
Mixing quantity of SiO2 W /wt%1 542 3
Qu
an
tifica
tio
n o
f S
i
ele
me
nt /w
t%
0
0.4
0.2
0.6
ν =500 mm2/s
20
Analysedportion
(i) W=0%, r =24.2% (ii) W =1wt%,r =34.8%
10μm
(a) SEM images on ironed cup surfaces, ν=500 mm2/s
(b) Quantification of Si element on sidewall of ironed cup 44
Conclusions
1. Seizure resistance in ironing of the aluminium alloy cupswas improved with the lubricant containing fine SiO2particles having size of 0.01 µm.
2. For ZrO2 or Al2O3 particles, seizure resistance wasequal to or inferior to the lubricant without fine particles.
3. Seizure resistance was effectively improved by applyingthe high viscosity lubricant with fine SiO2 particles.
45
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
46
TiN and VN coatings deposited by a direct current (DC) magnetron
sputtering PVD were utilised to improve seizure resistance in ironing of
aluminium alloy cups.
Uncoated high-speed steel die
Hardness: lowFriction: highSeizure resistance: low
Improvement of seizure resistance in ironing of
aluminium alloy cup using titanium nitride coated die
Coated high-speed steel dieHardness: Friction:
Seizure resistance:
Ironing die Seizure
1mm
Ironed cup
Low surface quality
Physical vapor deposition: PVD
DC magnetron
sputtering technique
Cathodic arc
technique
SKH51
Smooth
Coating
Rough
47
Surface roughness of coated discs
Before coating
After coating
Uncoated Cathodic arc TiN
225W-TiN 265W-TiN 225W-VN 265W-VN
Surf
ace r
oughness [
µm
Ra]
0
0.010
0.005
0.015
0.020
Coatings
0.025
48
Coatings
Load-t
o-f
ailu
re
[N]
0
20
40
60
80
(b) Load-to-failure of discs
Hardness and load-to-failure of coated discs
(a) Hardness of discs
Hard
ness [
HV
]
0
500
1000
1500
2500
2000
Coatings
3000
Aluminium adherence index of coated discs
in ring-on-disc test
Al adhere
nce inde
x
0
0.05
0.10
0.15
Coatings
0.20
Uncoated 225W-TiN500µm
Load
Ring-on-disc test
500µm
Aluminium Aluminium
AA1050 H14
SKH51
50
Surface roughness of ironed cups
Su
rfa
ce
ro
ug
hn
ess o
f
ironed c
up [μ
mR
a]
0
0.4
0.2
0.6
0.8
Number of strikes n
4020 3010 6050
Uncoated die
225W-TiN-coated die
Drawn cup
225W-TiN, n=10Uncoated, n=10
100µm
Severe seizure Small seizurePunch
(SKD11) Die (SKH51)
Drawn cupAA1050 H14
Ring
f 39.75
5
f 39.10
100mm/s
51
Conclusions
1. Cathodic arc TiN coating exhibited the highest hardnessand had the highest ability to resist cracking.
2. All of the coatings were effective in reducing aluminiumtransferred to the discs.
3. The 225W-TiN coating with a low degree of aluminiumtransfer performed well in ironing.
52
Chapter Contents
1 Introduction
2Ironing of stainless steel and aluminium alloy drawn cup using
TiCN-based cermet die
3Reduction in friction in ironing of stainless steel and aluminium
alloy drawn cup using die having lubricant pockets
4Lubrication behaviours in ironing of stainless steel cup with die
having lubricant pockets
5Improvement of lubrication in ironing of stainless steel cup by
surface roughening
6Lubricant containing fine particles for improving seizure
resistance in ironing of aluminium alloy cup
7Improvement of seizure resistance in ironing of aluminium alloy
cup using titanium nitride coated die
8 Concluding remarks
Reduction in Friction in Ironing of Aluminium Alloy
and Stainless Steel Drawn Cups
53
Future perspectives
Die having lubricant pockets + chlorine additive
Cup
Die
Enhancement, boundary lubrications
Suitable application for several
work materials, different
additives
Particles Hardness /HV Density /g·cm-3
SiO2 950 2.2
ZrO2 1230 5.68
Al2O3 1570 3.95
ZnO 418 5.61
CuO 229 6.14
A3003-O: 31HV, SKD11: 750HV, TiCN-based cermet: 1550HV
Lubricant + fine particles
54
SiO2 , lower hardness, well perform
List of publications and conference
1. 安部洋平,森謙一郎,畑下文裕,柴孝志,Witthaya Daodon,“潤滑剤ポケットを有する
ダイを用いたステンレス鋼容器のしごき加工における耐焼付き性の向上-潤滑剤ポケットを有するサーメットダイを用いたしごき加工 第1報-”,塑性と加工,56-658 (2015), 972-978.
2. Witthaya Daodon,安部洋平,森謙一郎,高橋尚志,“潤滑剤ポケットを有するダイを用
いたステンレス鋼容器のしごき加工における最適潤滑条件-潤滑剤ポケットを有するサーメットダイを用いたしごき加工 第2報-”,塑性と加工,57-660 (2016), 22-27.
3. Witthaya Daodon, Varunee Premanond, Witthawat Wongpisarn, Panadda
Niranatlumpong, “Vanadium nitride and titanium nitride coatings for anti-galling
behavior in ironing of aluminum alloy cups”, Wear 342-343 (2015), 279-287.
4. C.J. Tan, Y. Abe, W. Daodon, N. Takahashi, K. Mori, J. Purbolaksono, “Increase in
ironing limit of aluminium alloy cups with lubricants containing nanoparticles”,
Journal of Materials Processing Technology, 229 (2016), 804-813.
1. Yohei Abe, Tomohiro Fujita, Ken-ichiro Mori, Kozo Osakada, Takashi Shiba and
Witthaya Daodon, “Improvement of formability in ironing of stainless steel drawn
cups using low friction cermet dies”. 11th International Conference on Technology of
Plasticity, October 19-24, 2014, Nagoya, Japan.
2. Witthaya Daodon, Yohei Abe, Ken-ichiro Mori and Shingo Kato, “Improvement of
seizure resistance in cold extrusion of alminium alloy billet using die having
heterogeneous surface”. 7th JSTP International Seminar on Precision Forging, March
9-12, 2015, Nagoya, Japan. 55
Recommended