Tribology in Manufacturing Processes & Joining by Plastic Deformation

672 Pages·2014·95.085 MB·English

by  Peter Groche

Tribology in
Manufacturing Processes &
Joining by
Plastic Deformation

Edited by
Peter Groche
Tribology in
Manufacturing Processes &
Joining by Plastic Deformation

Selected, peer reviewed papers from the
6th International Conference on
Tribology in Manufacturing Processes &
Joining by Plastic Deformation,
June 22-24, 2014, Darmstadt, Germany
Edited by
Peter Groche
Copyright  2014 Trans Tech Publications Ltd, Switzerland

All rights reserved. No part of the contents of this publication may be reproduced or
transmitted in any form or by any means without the written permission of the
publisher.

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Volumes 966-967 of
Advanced Materials Research
ISSN print 1022-6680
ISSN cd 1022-6680
ISSN web 1662-8985

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Preface
The aim of the ICTMP 2014 is to present the latest developments in the research of tribological
aspects in manufacturing processes. Therefore, subjects like lubrication, surface treatment, simulation
or wear phenomena are in the scope of interest. Apart from the everlasting trend to more productive
and more environmentally benign tribo-systems and to the fundamental understanding of the
tribological regime, new trends in the broad field of tribology in manufacturing processes are
emerging. New orientations are given by the processing of new materials e.g. fiber material. Surface
hardening and texturing are also central in industrial evolution. In addition to the conferences held in
Gifu, Nyborg, Yokohama, Nice and Notre Dame this conference focuses also on the integration of
joining techniques into forming processes. The combination of joining and forming operations offers
a favorable material utilization along with a high productivity. Since many researchers contributed to
that field of research, the conference aims at summarizing recent developments. In addition to insights
into current research in the field of tribology, the presentations include practical guidelines for solving
tribological questions in an industrial environment.
Plenary keynotes of Prof. Niels Bay, Prof. Ken-ichiro Mori, Prof. Kazuhiko Kitamura and Prof. Pierre
Montmitonnet introduce the conference topics. Altogether, the “6th International Conference on
Tribology in Manufacturing Processes & Joining by Plastic Deformation” provides an international
forum for scientists and practicing engineers from different disciplines to exchange their ideas and
experiences. You will have the opportunity to actively contribute to discussions with your colleagues
in a relaxed atmosphere in order to stimulate the generation of new ideas and solutions for tribology
related challenges of our time.
I would like to thank all authors of the 74 contributions to this conference and especially the Scientific
Committee whose members worked hard to review the papers and improve their quality.

Peter Groche
Chairman, ICTMP 2014
Scientific Committee

Chairman

P. Groche, Germany

Members

A. Azushima, Japan
N. Bay, Denmark
S. Bruschi, Italy
B. Denkena, Germany
K. Dohda, USA
L. Dubar, France
C. Karadogan, Turkey
K. Kitamura, Japan
R. Kolleck, Austria
M. Liewald, Germany
P. Montmitonnet, France
K. Mori, Japan
G. Ngaile, USA
S. Schmid, USA
S. Stupkiewicz, Poland
E. Tekkaya, Germany
V. Premanond, Thailand
N. Mahayotsanun, Thailand
Table of Contents
Preface and Scientific Committee
Chapter 1: Plenary Keynotes
Off-Line Testing of Tribo-Systems for Sheet Metal Forming Production
N. Bay and E. Ceron 3
Combination of Plastic Upsetting Joining and Plastic Serration Joining of Disk and Shaft
K. Kitamura, H. Inishi, K. Hirota, Y. Ukai and K. Matsunaga 21
Joining Processes by Plastic Deformation
K. Mori 29
Two-Dimensional Roll Bite Model with Lubrication for Cold Strip Rolling
T. Dbouk, P. Montmitonnet and N. Legrand 48
Chapter 2: Wear and Friction Testing
Friction Measurement Device for Fiber Material Forming Processes
D. Huttel, P. Groche, A. May and M. Euler 65
Influences of Cobalt Content on the Physical and Tribological Properties of Cemented
Tungsten Carbide Used in Sheet Metal Forming Application
V. Premanond and O. Diewwanit 80
Development of a Heating System for a Spiral Tribometer to Investigate the Influence of
Temperature on Tribological Systems
A. Huskic, B. Mehic, M. Kasper and D. Vaught 87
The Influence of Initial Commutator Surface Roughness on Wear of the Starter Motor
Commutation System
T. Spremberg, I. Engler and B. Denkena 96
A Wear Damage Assessment of High Temperature Forging Tool
E. Cabrol, C. Boher, V. Vidal, F. Rezai-Aria and F. Touratier 103
Surface Textures and Friction Control in Microforming
S. Castagne, M. Taureza and X. Song 111
Identification of Local Lubrication Regimes on Textured Surfaces by 3D Roughness
Curvature Radius
C. Hubert, K.J. Kubiak, M. Bigerelle and L. Dubar 120
Chapter 3: Machining Operations
Effects of External Hydrostatic Pressure on Finished Surface in Silicon Cutting
M. Yoshino, Y. Shimizu, K. Kono and M. Terano 129
Investigating the Effect of Ultrasonic Vibration on Hole Accuracy in Drilling of Metal
Matrix Composites
M. Kadivar, J. Akbari and B. Vakili Azghandi 137
Micro Dimple Milling for Structured Surface
T. Matsumura, S. Takahashi, N. Nagase and Y. Musha 142
Topographic Wear Monitoring of the Interface Tool/Workpiece in Milling AISI H13 Steel
A. Pereira, J. Martínez, M.T. Prado, J.A. Pérez and T. Mathia 152
Evolution of Dynamic Recrystallization of AISI-1045 Steel under Critical Friction
Conditions
K. Le Mercier, M. Watremez, J. Brocail and L. Dubar 168
Mutual Effect of Groove Size and Anisotropy of Cylinder Liner Honed Textures on Engine
Performances
M. Yousfi, S. Mezghani, I. Demirci and M. El Mansori 175
b Tribology in Manufacturing Processes & Joining by Plastic Deformation
The Role of Tool Geometry and Process Parameters during Fly Shearing in Hot Rolling of
Steel
H. Torres, M. Varga, D. Horwatitsch, K. Adam and M. Rodriguez Ripoll 184
Rheological Investigation of MIM Feedstocks for Reducing Frictional Effects during
Injection Moulding
K.K. Rane and P.P. Date 196
Chapter 4: Sheet Forming
Wear Behaviour of Al-Si and Zn Coated 22MnB5 in Hot Stamping
P.F. Bariani, S. Bruschi, A. Ghiotti and F. Medea 209
Lubricant Film Breakdown and Material Pick-Up in Sheet Forming of Advanced High
Strength Steels and Stainless Steels when Using Environmental Friendly Lubricants
E. Ceron, M. Olsson and N. Bay 219
Micro-Plasto-Hydrodynamic Lubrication a Fundamental Mechanism in Cold Rolling
M. Laugier, R. Boman, N. Legrand, J.P. Ponthot, M. Tornicelli, J.I. Bech and Y. Carretta 228
Direct Evaluation of Coulomb Friction Coefficient from Sheet Strip Stretch Test on a
Cylinder Surface
C. Karadogan and H.A. Hatipoglu 242
Influence of Tool Steel Hard Phase Orientation and Shape on Galling
P. Karlsson, A. Gåård, P. Krakhmalev and J. Berhe-Larsson 249
Characterisation of Tool Coatings for Press Hardening
R. Müller and A. Mosel 259
Experimental and Numerical Investigations on Frictional Behaviour under Consideration of
Varying Tribological Conditions
M. Merklein, F. Zöller and V. Sturm 270
Chapter 5: Massive Forming
Development of Upsetting-Extrusion Type Tribometer for Evaluating Lubrication Coating
Performance in Cold Forging
Z.G. Wang, S. Komiyama and Y. Yoshikawa 281
Enhancement of Tribological Performance via Innovative Tooling Design for Extrusion
Processes
J.B. Lowrie and G. Ngaile 290
Influence of Flow Stress on Lubricating Abilty of Environmentally-Friendly Lubricant for
Aluminum Alloy Cold Forging
Y. Sagisaka, K. Hayakawa, T. Nakamura, I. Ishibashi and T. Nakakura 301
On the Importance of Thermo-Mechanical Modelling of the Double Cup Extrusion Test
D. Duran, C. Karadogan and I. Ozdemir 311
Tribological Aspects in Manufacturing Processes of Microstructured Components and their
Tribological Behavior in Operation
T. Schrader, M. Weschta, M. Merklein, S. Tremmel, U. Engel and S. Wartzack 323
Influence of Tribological Condition on Construction of Minute Parts in Micro-Meso
Extrusion of A6063 Alloy
N. Takatsuji, K. Dohda and T. Funazuka 336
Chapter 6: Lubrication and Surface Treatments
Tribological Behaviour of Corrosion Inhibitors in Metal Working Fluids under Different
Contact Conditions
A. Tomala, A. Naveira Suarez and M. Rodriguez Ripoll 347
Microorganisms as a Replacement for Metal Working Fluids
M. Redetzky, A. Rabenstein, B. Palmowski and E. Brinksmeier 357
A Comparative Study of the Tribological Behavior of Tin Powder Clad on the JIS SKD11
Tool Steel with the GTAW Method
Y.C. Lin, H.M. Chen and Y.C. Chen 365
Advanced Materials Research Vols. 966-967 c
Numerical Hybrid Fluid Structure Coupling: Application to Mixed Lubrication in Metal
Forming
R. Deltombe, A. Belotserkovets and L. Dubar 377
Improved Wear Resistance of AISI 304L by Cladding Boride Layers Using the GTAW
Process
Y.C. Lin, J.B. Bai and J.N. Chen 386
Influence of Machine Hammer Peening on the Tribology of Sheet Forming
M. Oechsner, J. Wied and J. Stock 397
Numerical Investigation of Lubricated Deep Rolling Process in a Complex Roller Path
J.J. Liou and T.I. El-Wardany 406
Affecting the Life Time of Roller Bearings by an Optimal Surface Integrity Design after
Hard Turning and Deep Rolling
B. Denkena, G. Poll, O. Maiß and T. Neubauer 425
Benefit of a Surface Nanocrystallization Treatment on Co28Cr6Mo Abrasive Wear
Properties
C. Demangel, A. Poznanski, V. Steenhout, A. Levesque, H. Benhayoune and D. Retraint 435
Chapter 7: Metallurgical Joining
Nanoscale Understanding of Bond Formation during Cold Welding of Aluminum and Steel
A. Altin, S. Wohletz, W. Krieger, A. Kostka, P. Groche and A. Erbe 445
Joining with Electrochemical Support: Cold Pressure Welding of Copper – Weld Formation
and Characterization
H.C. Schmidt, D. Rodman, O. Grydin, C. Ebbert, W. Homberg, H.J. Maier and G. Grundmeier 453
Mechanism of Forming Joining on Backward Extrusion Forged Bonding Process
Y. Yoshida, T. Ishikawa and T. Suganuma 461
Roll Bonding of Two Materials Using Temperature to Compensate the Material Strength
Difference
A. Melzner and G. Hirt 471
Development of a Testing Procedure to Determine the Bond Strength in Joining-by-
Forming Processes
A. Mikloweit, M. Bambach, M. Pietryga and G. Hirt 481
Magnetic Pulse Welding by Electromagnetic Compression: Determination of the Impact
Velocity
J. Lueg-Althoff, A. Lorenz, S. Gies, C. Weddeling, G. Goebel, A.E. Tekkaya and E. Beyer 489
A Novel Method to Investigate the Principles of Impact Welding: Development and
Enhancement of a Test Rig, Experimental and Numerical Results
C. Pabst, S. Sharafiev, P. Groche and M.F.X. Wagner 500
Formation of Joining Mechanisms in Friction Stir Welded Dissimilar Al-Ti Lap Joints
M. Krutzlinger, R. Marstatt, S. Suenger, J. Luderschmid, M.F. Zaeh and F. Haider 510
Realization of Al/Mg-Hybrid-Joints by Ultrasound Supported Friction Stir Welding -
Mechanical Properties, Microstructure and Corrosion Behavior
B. Strass, G. Wagner, C. Conrad, B. Wolter, S. Benfer and W. Fürbeth 521
Friction Press Joining of Laser-Texturized Aluminum with Fiber Reinforced
Thermoplastics
F.X. Wirth, A.N. Fuchs, P. Rinck and M.F. Zaeh 536
Chapter 8: Simulation of Joining Processes
Analysis of Material Behaviour in Experimental and Simulative Setup of Joining by
Forming of Aluminium Alloy and High Strength Steel with Shear-Clinching Technology
M. Müller, R. Hörhold, M. Merklein and G. Meschut 549
Material Characterization for FEA of the Clinching Process of Short Fiber Reinforced
Thermoplastics with an Aluminum Sheet
B.A. Behrens, R. Rolfes, M. Vucetic, I. Peshekhodov, J. Reinoso, M. Vogler and N. Grbic 557
Contribution for the Simulation of Tube-Bulk Forming by Lateral Extrusion of Flanges and
Collars in Light Weight Components
M. Kannewurf and M. Liewald 569
d Tribology in Manufacturing Processes & Joining by Plastic Deformation
Multiscale Modeling of Joining Processes under Consideration of the Thermo-Mechano-
Chemical Behaviour in the Interface
R. Kebriaei, I. Vladimirov and S. Reese 580
Chapter 9: Mechanical Joining
High Speed Joining by Laser Shock Forming
S. Veenaas and F. Vollertsen 597
Improvement of Joinability in Mechanical Clinching of Ultra-High Strength Steel Sheets
Using Counter Pressure
Y.H. Abe, S. Nishino, K. Mori and T. Kato 607
Softening of High-Strength Steel for Laser Assisted Clinching
J. Osten, P. Söllig, M. Reich, J. Kalich, U. Füssel and O. Keßler 617
Simulation Assisted Analysis of Material Flow in Roller Clinched Joints
D. Rill, M. Weiß, H. Hoffmann and W. Volk 628
Ultrasonic Assisted Clinching of Aluminium Alloy Sheets
F. Heßeln and M.C. Wanner 641
Integration of Piezoceramic Tube under Prestress into a Load Carrying Structure
M. Brenneis and P. Groche 651
Determination of Friction Coefficients of Interstice of a Shaft-Hub-Connection
Manufactured by Lateral Extrusion
F. Dörr, M. Funk, M. Liewald, H. Binz and M. Savino 659