Third Party Funds Group - Sub project
Start date : 01.03.2022
End date : 29.02.2024
In the research project "Close-to-series design of modified tool surfaces for low-lubrication deep drawing" (IGF project: 01IF22299N) the performance of diamond-like carbon (DLC) coatings on tool surfaces to reduce friction and wear during deep drawing is investigated. It is analyzed to which extent the lubricant use in deep drawing can be significantly reduced or completely eliminated. The starting point is the industrial challenge of reducing lubrication and cleaning processes in sheet metal forming to lower costs, process times, and environmental impact.
The focus is on DLC coating systems based on ta-C and a-C:H, which can reduce adhesive wear and improve the resulting component quality, particularly in the forming of aluminum sheets. Building on preliminary work from the DFG Priority Programme 1676, suitable coating systems are selected, characterized, and evaluated under near-industrial conditions. Various semi-finished products, tool geometries, surface conditions, and stress collectives are analyzed. The investigations include tribological model tests, numerical analyses, deep-drawing tests with demonstrator geometries, and long-term tests to evaluate wear behavior. In addition, a cost-benefit analysis is conducted to estimate the industrial added value for SMEs. The aim is to derive practical recommendations for the selection, design, and application of coated tools in sustainable deep-drawing processes.
In the research project "Close-to-series design of modified tool surfaces for low-lubrication deep drawing" (IGF project: 01IF22299N) the performance of diamond-like carbon (DLC) coatings on tool surfaces to reduce friction and wear during deep drawing is investigated. It is analyzed to which extent the lubricant use in deep drawing can be significantly reduced or completely eliminated. The starting point is the industrial challenge of reducing lubrication and cleaning processes in sheet metal forming to lower costs, process times, and environmental impact.
The focus is on DLC coating systems based on ta-C and a-C:H, which can reduce adhesive wear and improve the resulting component quality, particularly in the forming of aluminum sheets. Building on preliminary work from the DFG Priority Programme 1676, suitable coating systems are selected, characterized, and evaluated under near-industrial conditions. Various semi-finished products, tool geometries, surface conditions, and stress collectives are analyzed. The investigations include tribological model tests, numerical analyses, deep-drawing tests with demonstrator geometries, and long-term tests to evaluate wear behavior. In addition, a cost-benefit analysis is conducted to estimate the industrial added value for SMEs. The aim is to derive practical recommendations for the selection, design, and application of coated tools in sustainable deep-drawing processes.