TY - JOUR A1 - Hansen, B. A1 - Wagner, P. A1 - Purr, S. A1 - Merklein, M. T1 - Investigations of batch fluctuation regarding tribological conditions in series production of car body parts JF - International Journal of Material Forming N2 - Fluctuations of material properties are one reason for the occurrence of cracks and waviness in series production of car body parts. Especially fluctuating tribological conditions have an effect on the friction behavior and thus on the material flow. So far fluctuating material properties are not considered in the standard FE-simulation and consequently not in the tool design. In order to enhance the accuracy of the simulation result and thus improve the tool design regarding a robust process, the appearance of batch fluctuations has to be consistently understood. Therefore, the impact of varying lubricant quantities and roughness have been investigated. Several batches have been analyzed to identify the main influencing parameter regarding the friction behavior. Flat strip-drawing tests have been performed to determine the friction coefficient. The investigations have been performed by using material from the series production, as delivered. Since the amount of lubricant turns out to be the main influencing factor, the characteristics and appearance of the lubricant distribution has been analyzed in a further step. The analysis has shown that the distribution of the lubricant changes within one coil over the coil width and length. In addition, the time of storage has been identified as one main influencing factor on the homogeneity of the lubricant distribution over the coil width. Based on these findings, a method has been developed to map the series production conditions regarding the friction conditions in the simulation. Hence, simulations were performed using a side frame blank with different friction conditions, to investigate the impact on the forming result. The results reveal that by considering realistically existing tribological conditions, more scrap is to be expected compared to the conventional simulation. This leads to the conclusion that previous simulation results are too optimistic. Consequently, the introduced method offers the potential to optimize the tool design by considering fluctuating tribological conditions already in the process of development. Thus, it is possible to reduce scrap and increase productivity. KW - BEHAVIOR KW - friction KW - Material KW - SURFACE-ROUGHNESS KW - Tribology Y1 - 2021 U6 - https://doi.org/10.1007/s12289-020-01600-w VL - 14 IS - 5 SP - 871 EP - 884 PB - Springer Nature ER - TY - JOUR A1 - Hansen, B. A1 - Hoebler, Michael A1 - Purr, S. A1 - Meinhardt, J. A1 - Merklein, M. T1 - Basics for inline measurement of tribological conditions in series production of car body parts JF - IOP Conference Series: Materials Science and Engineering N2 - The quality of car body parts in series production is strongly dependent on the tribological behavior. Fluctuating material properties such as the sheet roughness and the amount of lubricant have an influence on the forming process. On the basis of large amounts of data it is possible to investigate the friction behavior in series production and to make process adjustments if required. Therefore, inline measurement systems have a great potential to detect the sheet roughness during the cutting process of blanks in the coil line. Furthermore, contactless systems are advantageous as they do not damage the surface. Nevertheless, the optical measuring is influenced by the lubricant layer on top of the surface. Therefore, the previously unknown impact of the lubricant on the measuring result is investigated. Within this study, stationary optical roughness measurements have been conducted using different amounts of lubricant on hot-dip galvanized EDT steel. The results demonstrate the influence of different amounts of lubricant on the sheet roughness measurement. Hence, it is possible to correct the inline measuring results and gain knowledge of fluctuating surface roughness. In addition, strip drawing test has been carried out to investigate the effect of fluctuating tribological conditions. Y1 - 2019 U6 - https://doi.org/10.1088/1757-899x/651/1/012050 VL - 651 PB - IOP Publishing ER -