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Effects of dry machining on process limits in micro rotary swaging (2012)

Kuhfuß, B.; Moumi, E.; Piwek, V.:

7th International Conference on MicroManufacturing (ICOMM 2012), March 12-14, 2012, Norris University Center, Northwestern University, Evanston IL, USA

Abstract

In the last years the trend is observed in manufacturing industry to reduce the use of lubricant or to avoid it completely. This is also true for forming processes. Due to some size effects in micro rotary swaging which is investigated within the collaborative research center 747 on the one hand there is a desire for lubricant-free processing on the other hand the process gives opportunities to realize it. This paper shows the process windows for the alloy 304 (1.4301) and pure aluminum Al99,5 in dry machining. For the materials mentioned in comparison to treatment with full-volume of lubricant an opposite trend can be observed: while the usable process window for the steel material is reduced, the aluminum has a significantly enlarged process window and for some parameter combinations forming is only possible without lubricant. In addition, other material properties such as hardness are affected by dry machining. Measures for a reliable dry micro rotary swaging have to be developed and some of them are addressed.