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Numerical analysis of the potential of deep drawing processes with hydrostatic pressure lubrication

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Abstract

Deep drawing is one of the most important forming procedures for the economic production of sheet metal components. Especially for high-volume parts, deep drawing is a very efficient method of fabrication with high utilization of semi-finished parts. Certainly, conventional deep drawing processes are restricted by forming limits due to part failure during the drawing process. The process force is one of the most important factors for this restriction. The narrow process window, especially for deep drawing of light-weight materials, can be extended by reducing the friction forces at the die radius, using hydrostatic pressure lubrication. After the numerical analysis of the appearing loads of deep drawing processes, the optimal position for the insertion of pressurized lubricant was identified and the potential of the hydrostatic pressure lubrication was predicted. With experimental tests, the results of the simulations were approved. Both, the simulations and the experimental tests showed a significant reduction of the process forces.

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Acknowledgments

The investigations presented in this paper were carried out within the research project “Tribological optimization of deep drawing processes using servo presses” sponsored by Arbeitsgemeinschaft industrieller Forschungsvereinigungen “Otto von Guericke” e.V. (AiF), and Europäische Forschungsgesellschaft für Blechverarbeitung e.V. (EFB). At the same time, the authors would like to thank the following companies for their continuous and profound support during the project: Daimler AG, Filzek TRIBOtech, Fissler GmbH, Raziol Zibulla & Sohn GmbH, Hubert Stüken GmbH & Co. KG, and Zeller + Gmelin GmbH & Co. KG.

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Authors and Affiliations

  1. Institute for Production Engineering and Forming Machines (PtU), Petersenstr. 30, 64287, Darmstadt, Germany

    P. Groche & N. Moeller

  2. Lech-Stahlwerke GmbH, Industriestrasse 1, 86405, Meitingen, Germany

    C. Kloepsch

Authors
  1. P. Groche
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  2. C. Kloepsch
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  3. N. Moeller
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Correspondence to N. Moeller.

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Groche, P., Kloepsch, C. & Moeller, N. Numerical analysis of the potential of deep drawing processes with hydrostatic pressure lubrication. Prod. Eng. Res. Devel. 6, 157–167 (2012). https://doi.org/10.1007/s11740-012-0374-x

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  • DOI: https://doi.org/10.1007/s11740-012-0374-x

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