Tribological DLC-Coatings in Combination with Surface Texturing for Forming Tools to Increase Lifetime and to Improve Process Quality (B04)

Third Party Funds Group - Sub project

Overall project details

Overall project: TRR 73: Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen - Blechmassivumformung -

Overall project speaker:
Prof. Dr.-Ing. Marion Merklein (Institute of Manufacturing Technology)


Project Details

Project leader:
Dr.-Ing. Stephan Tremmel
Prof. Dr.-Ing. Sandro Wartzack
Prof. Dr. Harald Meerkamm


Contributing FAU Organisations:
Lehrstuhl für Konstruktionstechnik
Technische Fakultät

Funding source: DFG / Sonderforschungsbereich / Transregio (SFB / TRR)
Start date: 01/01/2009
End date: 31/12/2020


Research Fields

Tribologische PVD-/PACVD-Schichten
Lehrstuhl für Konstruktionstechnik


Abstract (technical / expert description):

The objective of the Transregional Collaborative Research Centre on Sheet-Bulk Metal Forming (CRC/TR 73), to combine the advantages and design possibilities of sheet metal and bulk metal forming in the production process of sheet bulk metal forming (BMU), is accompanied by high demands on the forming tool. Targeted local friction conditions on the tool surface are essential for effective control of the material flow. Only in this way, it is possible to form complex form elements of the sheet metal components while maintaining high quality requirements and at the same time avoiding undesirable changes in the components' geometry. In addition, the tool life is primarily limited by adhesive wear.

With the research of tribological DLC-coatings, the subproject B4 contributes to the development of active tool surfaces with a tribological behaviour adapted to the forming process. Among the group of DLC-coatings, tungsten-modified hydrogen-containing amorphous carbon coatings (a-C:H:W) show the most advantageous property profile for tool coating in application-oriented model tests and material analyses. They are characterized in particular by a low coefficient of friction and low wear. With the aid of statistical test methods, it is possible to predict and specifically adjust characteristic coating properties. By using different masking and ablation strategies, coatings of different tribological behavior can be combined on one surface and thus locally adapted friction can be realized.

Based on a-C:H:W coatings, which were continuously developed in the first two phases regarding a targeted friction adjustment, the extent to which the coatings can also contribute to an effective extension of the tool life will be focused in the current funding period. The coatings' fatigue life and wear resistance are further increased by multilayer and multi-phase coating architectures and substrate pretreatment measures. The contribution of the coatings to process-adapted friction conditions is being analyzed in application-oriented model and real tests. In addition, a complementary sensory function is implemented in the coatings. By recording electrical parameters in coating systems with high- and low-resistance layers, it will be possible to detect coating wear and thus predict the coating's life time more precisely and tool-specifically.


Publications
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Weikert, T., & Tremmel, S. (2019). Dünnschichtsensoren zur Verschleißdetektion als Beitrag zur Auslegung intelligenter Werkzeuge – eine Machbarkeitsstudie. In Tagungsband 4. Industriekolloquium Blechmassivumformung 2019 - DFG Transregio 73. Hannover, DE.
Marian, M., Weikert, T., & Tremmel, S. (2019). Numerical and Experimental Studies on Friction Reduction by Surface Modification in TEHL Contacts. In Proceedings of the 74th STLE Annual Meeting & Exhibition. Nashville, Tennessee, US.
Weikert, T., & Tremmel, S. (2018). Wear Detection using Carbon-Based Sensor Coatings – a novel approach. In Proceedings of The 18th Nordic Symposium on Tribology – NORDTRIB 2018. Uppsala, SE.
Kersting, P., Gröbel, D., Merklein, M., Peter, S., Wernicke, S., Tekkaya, A.E.,... Willner, K. (2016). Experimental and numerical analysis of tribological effective surfaces for forming tools in Sheet-Bulk Metal Forming. Production Engineering, 10(1), 37-50. https://dx.doi.org/10.1007/s11740-015-0651-6
Weikert, T., Tremmel, S., & Wartzack, S. (2016). Gezielte Anpassung lokaler Reibungszustände unter Einsatz wolframmodifizierter amorpher Kohlenstoffschichten. Tribologie und Schmierungstechnik, 63(5), 5 - 11.
Weikert, T., & Tremmel, S. (2016). Influence of bias voltage and layer thickness variation on mechanical properties and tribological behavior of a-C:H:W multilayer coatings. In Proceedings of the 17th Nordic Symposium on Tribology - NORDTRIB 2016. Aulanko, Hämeenlinna, FI.
Löffler, M., Andreas, K., Engel, U., Weikert, T., Tremmel, S., Wartzack, S.,... Merklein, M. (2016). Surface modifications for adaption of tribological conditions in sheet-bulk metal forming processes. In Bobzin, K.; Bouzakis, K.-D.; Denkena, B.; Maier, H.J.; Merklein, M. (Eds.), Proceedings THE "A" Coatings (pp. 13-20). Hannover, DE: Garbsen: PZH Verlag.
Löffler, M., Andreas, K., Engel, U., Schulte, R.K., Gröbel, D., Krebs, E.,... Merklein, M. (2016). Tribological measures for controlling material flow in sheet-bulk metal forming. Production Engineering, 10(4), 459 - 470. https://dx.doi.org/10.1007/s11740-016-0695-2
Weikert, T., Tremmel, S., & Wartzack, S. (2015). Gezielte Anpassung lokaler Reibungszustände unter Einsatz wolframmodifizierter amorpher Kohlenstoffschichten (a-C:H:W). In Gesellschaft für Tribologie e.V. (Hrg.), 56. Tribologie-Fachtagung. Reibung, Schmierung und Verschleiß. Band I (pp. 24/1 - 24/10). Göttingen, DE: Aachen: Gesellschaft für Tribologie e.V..
Zhao, R., Weikert, T., Tremmel, S., & Wartzack, S. (2015). Tribological behaviour of tungsten doped hydrogenated amorphous carbon coatings deposited under various bias voltages and argon flows. Poster presentation at Coatings Science International, Noordwijk, NL.

Last updated on 2019-21-06 at 15:17