Review on Development and Testing of New Tribology Systems for Sheet Metal Forming

The increasing focus on environmental issues in industrial production has resulted in various attempts to develop new, environmentally friendly tribology systems for metal forming in order to substitute hazardous lubricants such as chlorinated paraffin oils. The authors have been engaged in a framework program ‘SHETRIB - New environmentally benign sheet metal forming tribology systems’ in collaboration with Danish and Swedish industry. A number of new solutions are presented: (i) further development of a methodology for off-line testing of new, environmentally friendly lubricants, (ii) successful testing and introduction of new, environmentally benign lubricants in industry, (iii) development of a tool coating diminishing the risk of galling in sheet stamping and ironing of tribologically difficult workpiece materials such as stainless steel, and (iv) development of tailored tool surfaces enhancing micro-plastohydrodynamic lubrication in deep drawing and ironing. Different ways to detect the onset of galling are also presented including acoustic emission, a promising alternative for on-line production monitoring.