Using stamping punch force variation for the identification of changes in lubrication and wear mechanism
Voss, B. M., Pereira, M. P., Rolfe, B. F. and Doolan, M. C. 2017, Using stamping punch force variation for the identification of changes in lubrication and wear mechanism, in IDDRG 2017: Materials Modelling and Testing for Sheet Metal Forming : Proceedings of the International Deep Drawing Research Group, IOP Publishing, Bristol, Eng., pp. 1-8, doi: 10.1088/1742-6596/896/1/012028.
The growth in use of Advanced High Strength Steels in the automotive industry forlight-weighting and safety has increased the rates of tool wear in sheet metal stamping. This isan issue that adds significant costs to production in terms of manual inspection and partrefinishing. To reduce these costs, a tool condition monitoring system is required and a firmunderstanding of process signal variation must form the foundation for any such monitoringsystem. Punch force is a stamping process signal that is widely collected by industrial pressesand has been linked closely to part quality and tool condition, making it an ideal candidate as atool condition monitoring signal. In this preliminary investigation, the variation of punch forcedue to different lubrication conditions and progressive wear are examined. Linking specificpunch force signature changes to developing lubrication and wear events is valuable for die wearand stamping condition monitoring. A series of semi-industrial channel forming trials wereconducted under different lubrication regimes and progressive die wear. Punch force signatureswere captured for each part and Principal Component Analysis (PCA) was applied to determinethe key Principal Components of the signature data sets. These Principal Components werelinked to the evolution of friction conditions over the course of the stroke for the differentlubrication regimes and mechanism of galling wear. As a result, variation in punch forcesignatures were correlated to the current mechanism of wear dominant on the formed part; eitherabrasion or adhesion, and to changes in lubrication mechanism. The outcomes of this studyprovide important insights into punch force signature variation, that will provide a foundationfor future work into the development of die wear and lubrication monitoring systems for sheetmetal stamping.
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