Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

Chengliang HU; Shogo OSAKI; Baixuan CAI; Mitsuru AOYAMA; Kuniaki DOHDA

doi:10.1007/s40544-022-0717-3

Friction 2023, 11(10): 1862-1876 https://doi.org/10.1007/s40544-022-0717-3

Research Article |

Open Access | Issue | Published: 30 March 2023

Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

Show Author's Information Hide Author's Information Chengliang HU^¹(

), Shogo OSAKI^², Baixuan CAI^¹, Mitsuru AOYAMA^², Kuniaki DOHDA^³

1 Institute of Forming Technology & Equipment, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200030, China

2 Central Research Laboratories, Nihon Parkerizing Co., Ltd., Hiratsuka-shi 254-0012, Japan

3 Department of Mechanical Engineering, Northwestern University, Evanston 60208-3111, USA

Keywords:

lubrication, optimization, sensitivity, friction factor (m), forming load, cold forging

Cite this article:

HU C, OSAKI S, CAI B, et al. Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method. Friction, 2023, 11(10): 1862-1876. https://doi.org/10.1007/s40544-022-0717-3

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Abstract

This study evaluated dry-in-place lubricants used for cold forging. A group of isothermal compression tests with a strain rate $(\dot{ε})$ range of 0.001–1 s⁻¹ and temperature (T) range of 30–400 °C were completed. The flow stress (σ) curves of annealed steel S45C were obtained, and a corresponding Hensel–Spittel model was developed to support finite element (FE) simulation. The sensitivity of the steady combined forward and backward extrusion (SCFBE) test proposed in another study was improved by approximately 20% after it was optimized using the results of the FE simulations. Key parameters were identified, and the calibration curves after optimization were obtained. On the basis of the optimized test, a friction testing setup with a heating system was developed, in which the die temperature could be adjusted from room temperature (RT) to 230 °C. Three dry-in-place lubricants and conventional phosphating lubricant were tested, and the friction factors (m), forming loads, and ejection loads were measured. The surface features of the specimens after testing were also investigated. According to the testing results, of the three tested dry-in-place lubricants, the mica type was the best. In addition, the optimized friction testing design was verified as effective.

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Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

Show Author's information Hide Author's Information Chengliang HU^¹(

), Shogo OSAKI^², Baixuan CAI^¹, Mitsuru AOYAMA^², Kuniaki DOHDA^³

1 Institute of Forming Technology & Equipment, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200030, China

2 Central Research Laboratories, Nihon Parkerizing Co., Ltd., Hiratsuka-shi 254-0012, Japan

3 Department of Mechanical Engineering, Northwestern University, Evanston 60208-3111, USA

Abstract

Keywords: lubrication, optimization, sensitivity, friction factor (m), forming load, cold forging

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Publication history

Received: 15 February 2022

Revised: 14 June 2022

Accepted: 31 October 2022

Published: 30 March 2023

Issue date: October 2023

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Acknowledgements

This research was partially supported by the National Natural Science Foundation of China (NSFC; No. 51875348).

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