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Basics for inline measurement of tribological conditions in series production of car body parts
(2019)
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.
In the forming tools for pressing car body parts, heavy blankholders are used to prevent buckling and wrinkling of the blank. During each press cycle, those large masses need to be lifted, raising thereby the structural dynamic load on the forming tool and on the press. Therefore a detailed knowledge about the forming tool dynamics is essential for an accurate and robust design of forming tools. In this paper, a dynamic finite element method (FEM) simulation of selected automotive forming tool is presented enabling identification of regions of critical stresses. For validation of the simulation results, the kinematic responses of the tool's components are compared with the measurements obtained in an experiment.