The 20th International ESAFORM Conference on Material Forming (ESAFORM 2017), 26th-28th April 2017, Dublin/Ireland
In dry metal forming processes, the heat dissipation is a critical issue. The cooling by the lubricant is missing. The different heat evolution affects the machine and the process and thus the final product. For the machine the thermal expansion is affected and needs to be considered. Also the tools can bear only a maximum heat load before they get damaged. Furthermore, the heat can influence the material properties like the flow stress if it exceeds a critical value. Furthermore, the process forces and the material flow are directly affected. In addition, heat modifies in combination with plastic strain the generated microstructure of the workpiece. If the heat is high enough even positive effects of cold forming like work hardening are drastically decreased. In summary, the heat evolution during lubricated and dry forming processes need to be investigated.
The evolution of heat in rotary swaging was investigated with conventional tools and machine settings. This was realized by varying the feeding velocity for the lubricated forming of aluminum tubes (3.3206) and steel tubes (1.0308). Moreover, the steel tubes are also formed with conventional tools by dry rotary swaging. A temperature measurement was integrated inside the tubes during the rotary process. Thus, the heat evolution inside the tube during the process at two different positions was examined. Also the variation between inside the tubes and the surface of the tubes was investigated by measuring the temperature at the surface directly after the forming process. Comparisons between different measured heat evolutions represent the impact of lubrication, feed rate and material. Thus, the practicability and the challenge for dry forming processes are presented.