角筒絞り成形における焼付き現象に関する研究

Title 角筒絞り成形における焼付き現象に関する研究( 本文_{(Fulltext) )}

Author(s) YANG, MINGXU

Report No.(Doctoral Degree) 博士(工学) 甲第449号 Issue Date 2014-03-25 Type 博士論文 Version ETD URL http://hdl.handle.net/20.500.12099/49018 ※この資料の著作権は、各資料の著者・学協会・出版社等に帰属します。

1

Galling behavior in square cup drawing

2 1 ... 1 1.1 ... 1 1.1.1 ... 1 1.1.2 ... 2 1.2 ... 8 1.2.1 ... 9 1.2.2 ... 10 1.3 ... 11 1.4 ... 12 2 ... 13 2.1 ... 13 2.1.1 ... 13 2.1.2 ... 13 2.2 ... 16 2.2.1 ... 16 2.2.2 ... 16 2.3 ... 19 2.3.1 ... 19 2.3.2 ... 21

3 2.3.3 ... 26 2.4 ... 27 2.4.1 ... 27 2.4.2 ... 29 2.5 ... 34 3 FEM ... 36 3.1 FEM ... 36 3.2 ... 38 3.3 ... 39 3.3.1 ... 39 3.3.2 ... 42 3.4 ... 45 3.5 ... 46 3.6 ... 41 3.6.1 ... 49 3.6.2 ... 52 3.7 ... 54 3.8 ... 58 4 ... 59 4.1 FEM ... 59

4 4.2 FEM ... 59 4.3 ... 65 4.3.1 ... 65 4.3.2 ... 68 4.4 ... 70 5 ... 71 5.1 ... 71 5.2 ... 71 5.3 ... 75 5.4 ... 80 5.5 ... 81 6 ... 83 ... 86 ... 88 ... 89

5

1

6

Rz

Fig.1.1

Fig.1.1 Galling on product in sheet metal forming

1.1.2

7

16),17)

18),19)

Fig.1.2 Effect of roll roughness on maximum temperature in roll bite

Reduction /% M ax im um t em pe ra tu re i n ro ll b it e /

8

Fig.1.3 Shape of beginning point of heat streak

Figs.1.4 1.7 20)~23)

9

Fig.1.4 Strip tension-compression type friction test

Fig.1.5 U-bending type friction test

Die Die N F Strip Die Die N Strip Blank holder Blank holder Punch

10

Fig.1.6 Ironing type friction test

Fig.1.7 Draw bead type friction test

T Strip Die N F Strip Bead N F

11 Fig.1.4 MPa Fig.1.5 Fig.1.6 Fig.1.7 (1) (2) (3) (1) (2) (3) (4) (5) (1) (2)

12 (3) 24) l p (1.1) 25) p l = C

13 1.2.1 CO2 100kg 1km/l 26) 3/4 90 300MPa 440MPa 1470MPa 27) Fig.1.8 28)

14

Fig.1.8 Fact and forecast of high strength steel rate for automobile bodies

FEM 29) 1.2.2 30)~32) H ig h St re ng ht h st ee lo r at e / Year

15 33) 34) ( ) 35) 36) 1.3 36)

16 1.4 1 2 3 FEM 4 3 FEM 5 FEM 6

17

2

18 A-A section

Fig.2.1 Illustration of square cup drawing test

19

(a) Blank shape (b) Drawn cup

Fig.2.2 Drawn cup

Fig.2.3 Thickening during drawing

Bent zone Drawn zone Drawn zone 54 54 4-R15 t = 2.0 mm

20 2.2 2.2.1 AC H1F110 Fig.2.4 Fig.2.5 Fig.2.6 Fig2.7 3 2.2.2 Table 2.1 2.0mm SPFC590 SKD11 Rz R 5.0mm H 10 15 20mm 3 C 2.0mm 0 18kN 2 P460 40mm/s

21

Fig.2.4 General view of servo-press

Fig.2.5 General view of drawing tools

Blank holder Punch Die

22

Table 2.1 Experimental conditions

Blank Die

Fig.2.6 Shape of blank and die

Fig.2.7 Surface appearance of blank

Blank

Material SPFC590(by JIS)

(Tensile strength 625 MPa)

Thickness, t /mm 2.0 Surface Roughness, Rz 3.9 Die Material SKD11 Surface Roughness, Rz 0.7 High, H /mm 10 15 20 Punch material SKD11 Clearance between

punch and die, C /mm 2.0

Blank holder force, F /kN 0, 18

Lubricant P460

(1500×10-6 m2/s at 25 °C)

23 2.3 2.3.1 H = 20mm 0 18kN Fig.2.8 F = 0kN F = 18kN (a) F = 0kN (b) F = 18kN

Fig.2.8 Galling position on die and drawn cup surface

Figs.2.9~2.11

24

Fig.2.9 Galling on die and drawn cup surface (H = 20mm, F = 0kN)

+

Fig.2.10 Galling on die and drawn cup surface (H = 15mm, F = 0kN)

Drawn cup Die N = 5 N = 3 N = 1 Drawn cup Die N = 5 N = 3 N = 1 N = 10

25

Fig.2.11 Galling on die and drawn cup surface (H = 10mm, F = 0kN)

2.3.2 Fig.2.12 H = 20mm F = 0kN N = 1 4 Fig.2.13 A B R C R D Drawn cup Die N = 5 N = 3 N = 1 N = 10

26

Fig.2.12 Drawing load curve (H = 20mm F = 0kN N=1)

(a) Point A in Fig. 2.12 (b) Point B in Fig. 2.12

(c) Point C in Fig. 2.12 (d) Point D in Fig. 2.12

Fig.2.13 Deformation state of blank during drawing

0 20 40 60 80 100 120 0 10 20 30 40 D ra w in g lo ad /k N Punch stroke /mm A B C D

27 Fig.2.14 F = 18kN N = 1 3 1 85kN 2 100kN Fig.2.15 N = 1 F = 0kN H H Figs.2.10~2.12 1 85kN 2 100kN Fig.2.16 F = 0kN 1 85kN 2 105kN F = 18kN 1 105kN 2 100kN Fig.2.17 1 2 Fig.2.13 D 2 Fig.2.18(a) Fig.2.13 D Fig.2.18(b) F = 0kN F = 18kN 2 2 2

28

Fig.2.14 Drawing load with different drawing cycle (H = 20mm, F =0kN)

Fig.2.15 Drawing load with different die height (N = 1, F =18kN)

0 20 40 60 80 100 120 0 10 20 30 40 D ra w in g lo ad /k N Punch stroke /mm H20 H15 H10 0 20 40 60 80 100 120 0 10 20 30 40 D ra w in g lo ad /k N Punch stroke /mm N = 1 N = 3 H = 10mm H = 15mm H = 20mm N = 3 N = 1

29

Fig.2.16 Drawing load with different blank holder force(H = 20mm, N = 1)

Fig.2.17 Drawing load with the different blank holder force(Blank holder force is

cut off) 0 20 40 60 80 100 120 0 10 20 30 40 D ra w in g lo ad /k N Punch stroke /mm F=0 F=18 F = 0kN F = 18kN 0 20 40 60 80 100 120 0 10 20 30 40 D ra w in g lo ad B la nk h ol de r fo rc e /k N Punch stroke /mm F=18,F-18 F=0 F = 18kN F = 0kN

30

(a) (b)

Fig.2.18 Shape of drawn cup of (d) in Fig.2.13

2.3.3

Fig.2.19

Fig.2.19 Schematic image of galling position and growing process

Drawn zone Drawn zone Bent zone Drawn zone Drawn zone Bent zone

31 2.4 2.4.1 KEYENCE VHX-600 S-3000N H = 15mm F = 0kN N = 3 Fig.2.20 Fig.2.21 Fig.2.22 N=1 N=1 2 3 Fig.2.23 (a) (b) 1mm (B ) (H ) Fig.2.20 Microscope

32

Fig.2.21 Scanning electron microscope

Fig.2.22 Observation point of drawn cup(N=3) Dull surface

Glossy surface Galling

33 (a)

(b)

Fig.2.23 Observation point of die

2.4.2 Figs.2.24~2.28 Fig.2.24 Fig.2.25 Fig.2.26 N = 1 Fig.2.27 N = 2 Fig.2.28 N = 3 N = 1 A1 A4 A2 A3

34

N = 2 3

Fig.2.24 Dull surface

35

Fig.2.26 Galling position on drawn cup (N = 1)

Fig.2.27 Galling position on drawn cup (N = 2)

Fig.2.28 Galling position on drawn cup (N = 3)

Galling

36 Figs.2.29~2.32 Fig.2.29 A1 SEM Fig.2.30 SEM A2 SEM Fig.2.31 A3 SEM Fig.2.32 A4 SEM 1000 times 3000 times

Fig.2.29 Surface appearance of die (A1)

37

1000 times 2000 times

Fig.2.30 Surface appearance of die (A2)

1000 times 3000 times

Fig.2.31 Surface appearance of die (A3)

Drawing direction

38

1000 times 2000 times

Fig.2.32 Surface appearance of die (A4)

2.5 (1) 1. ( ) R (2) (3) Drawing direction

39 (4)

40

3

FEM

41

Before drawing After drawing

Fig.3.1 Simulation model

Fig.3.2 Stress-Strain curve

Strain St re ss / M P a

42 3.2 0.03 0.06 0.12 FEM Fig.3.3 FEM = 0.06 = 0.12 0.06

Fig.3.3 Drawing load by FEM simulation and experiment(F = 0kN)

Punch stroke /mm D ra w in g lo ad / kN = 0.06 = 0.12 Experiment = 0.03

43 3.3 3.3.1 FLIR SC7500S 320 256 Fig.3.4 19.7 19.6 43mm 0.01s/ FEM

Fig.3.4 Temperature measurement by thermo-camera

25 50 75 100 125 150

=0.3 Fig.3.5

44

x

Fig.3.5 Dull surface zone and glossy surface zone on drawn cup surface

Fig.3.6 Correction graph for dull surface zone

Glossy surface zone Dull surface zone

45

Fig.3.7 Correction graph for glossy surface zone

Fig.3.8 Fig.3.8 (b)

Fig.3.8 (b)

Fig.3.9

Fig.3.8 Projection area on drawn cup and thermography

46

Fig.3.9 Temperature distribution at the moment of drawn cup sliding out from die

3.3.2 FEM 20W/(m2 K) 11000W/(m2 K) ( ) 5000 11000 15000 20000W/(m2 K) Figs.3.10~13 20000 W/(m2 K) . / 1 2 3 4 5 22 p d c b a

47

Fig.3.10 Temperature distribution by FEM simulation at the moment of drawn cup

sliding out from die( = 5000W/(m2 K))

Fig.3.11 Temperature distribution by FEM simulation at the moment of drawn cup

sliding out from die( = 11000W/(m2 K))

/ 1 2 3 4 5 22 p d c b a Higher than 100 / 1 2 3 4 5 22 p d c b a Higher than 100

48

Fig.3.12 Temperature distribution by FEM simulation at the moment of drawn cup

sliding out from die( = 15000W/(m2 K))

Fig.3.13 Temperature distribution by FEM simulation at the moment of drawn cup

sliding out from die( = 20000W/(m2 K))

/ 1 2 3 4 5 22 p d c b a Higher than 100 1 2 3 4 5 22 p d c b a /

49 3.4 DEFORM-3D Fig.3.14 Fig.3.15 4 R R 2 0.5 mm 0.5 mm 4 R 0.5 mm 10 R 4 10

Fig.3.14 Measurement points on die surface

Fig.3.15 Measurement points on drawn cup surface

Drawing zone R shoulder of drawing zone Bending zone R shoulder of bending zone Bent zone Drawn zone

50

Fig.3.16

D4

Die Drawn cup

Fig.3.16 Projective figures on die and drawn cup surface

3.5 Fig.3.17 D4 1 2 3 4 5 20 P D C B A _{1 2} 3 4 5 22 p d c b a

51

(a) Variation curve of contact pressure at D4 point

(b) Variation curve of temperature at D4 point

Fig.3.17 Definition of tribological parameters

Sliding distance

Friction work

Maximum pressure

52 FEM 1 0.01mm 20 (0.2mm) 4700 n n1,n20, n4700 p W L T max pmax (3.1) . pmax =Max(pni) i (1,20,40,∙∙∙4700)

53 L = N Sn

54

Fig.3.18 Maximum pressure at measurement points on die surface

Fig.3.19 Friction work at measurement points on die surface

1 2 3 4 5 20 P D C B A / G P a Galling position 1 2 3 4 5 20 P D C B A / G P a × m m Galling position

55

Fig.3.20 Sliding distance at measurement points on die surface

Fig.3.21 Maximum temperature at measurement points on die surface

1 2 3 4 5 20 P D C B A / m m Galling position 1 2 3 4 5 20 P D C B A / Galling position

56 3.6.2 Figs.3.22~3.25 Fig.3.22 Fig.3.23 Fig.3.24 Fig.3.25

Fig.3.22 Maximum pressure at measurement points on drawn cup surface

1 2 3 4 5 p d c b a / G P Galling position

57

Fig.3.23 Friction work distribution at measurement points on drawn cup surface

Fig.3.24 Sliding distance at measurement points on drawn cup surface

1 2 3 4 5 22 p d c b a / G P a m m Galling position 1 2 3 4 5 22 p d c b a / m m Galling position

58

Fig.3.25 Maximum temperature at measurement points on drawn cup surface

3.7 g17 Fig.3.25 g17 Fig.3.26 R Fig.3.27 g17 1 2 3 4 5 22 p d c b a / Galling position

59

Fig.3.26 Variations of wall thickness and temperature at point g17 during forming

for square blank

60 Fig.3.26

Fig.3.28

g17 Fig.3.25

Fig.3.28 Wall thickness in history deformation at measurement points on drawn

cup

61

Fig.3.29 Variations of contact pressure and temperature at point g17 during

forming for square blank

g17 21mm 21mm Fig.3.30 g17 R g17 R R

62

Fig.3.30 Forming state of cup at punch stroke 21mm

3.8

F E M

(1)

63

4

Fig.4.1 Blank shape of octagon and tricontadigon (b) Tricontadigon

54 54 (0, 0) (27, 0) (25.3, 10.3) (26.2, 6.7) (22.7, 14.6) (19.1, 19.1) y x (a) Octagon 54 54 4-C15

64

(a) Octagon (b) Tricontadigon

Fig.4.2 Drawn cup of otagon and tricontadigon

Fig.4.3 Die height

4.2 FEM FEM Fig.4.4 Fig.4.5 p16 160 n15 160 Fig.4.6 Fig.4.7 p16 n15 H

65

Fig.4.4 Maximum temperature in history deformation at measurement points on

octagon drawn cup surface

Fig.4.5 Maximum temperature in history deformation at measurement points on

Tricontadigon drawn cup surface

1 2 3 4 5 18 p d c b a / p16 1 2 3 4 5 15 p d c b a / n15

66

Fig.4.6 Maximum wall thickness in history deformation at measurement points on

octagon drawn cup surface

Fig.4.7 Maximum wall thickness in history deformation at measurement points on

Tricontadigon drawn cup surface

1 2 3 4 5 18 p d c b a /mm p16 1 2 3 4 5 15 p d c b a /mm n15

67

p16 n15 - Fig.4.8 Fig.4.9

Fig.4.10 Fig.4.11

Fig.4.8 Variations of wall thickness and temperature at point p16 during forming

for octagon blank

Contact exit Punch stroke /mm W al l t hi ck ne ss / m m T em pe ra tu re /

68

Fig.4.9 Variations of wall thickness and temperature at point n15 during forming

for tricontadigon blank

Fig.4.10 Variations of contact pressure and temperature at point p16 during

forming for octagon blank

Contact exit Contact exit Punch stroke /mm Punch stroke /mm W al l t hi ck ne ss / m m T em pe ra tu re / T em pe ra tu re / C on ta ct p re ss ur e /G P a

69

Fig.4.11 Variations of contact pressure and temperature at point n15 during

forming for tricontadigon blank

g17 p16 n15 4.3 4.3.1 2 0 FEM Figs.4.12 4.14 Contact exit Punch stroke /mm T em pe ra tu re / C on ta ct p re ss ur e /G P a

70

Fig.4.15 4.17

Fig.4.12 Galling position on drawn cup for square blank (F = 0 kN)

Fig.4.13 Galling position on drawn cup for octagon blank (F = 0 kN)

0.3 mm1 mm

0.3 mm 1 mm

71

Fig.4.14 Galling position on drawn cup for tricontadigon blank (F = 0 kN)

Fig.4.15 Galling position on die for square blank (F = 0 kN)

Fig.4.16 Galling position on die for octagon blank (F = 0 kN)

0.3 mm 1 mm

1 mm 1 mm

72

Fig.4.17 Galling position on die for tricontadigon blank (F = 0 kN)

4.3.2

Fig.4.18

73

Fig.4.18 Relationship between galling starting drawing cycle and die height

8)

F = 12 kN F = 0 kN

74 Figs.4.12 4.14

4.4

(1)

75

5

Fig.5.1 Stress-Strain curve at each F value

F =800 F =1000 F =1200 F =1500 St re ss / M P a Strain

76

Fig.5.2 Maximum temperature at measurement points on drawn cup surface

for F = 800MPa

Fig.5.3 Maximum temperature at measurement points on drawn cup surface

for F = 1000MPa g17 1 2 3 4 5 22 p d c b a / g17 1 2 3 4 5 22 p d c b a /

77

Fig.5.4 Maximum temperature at measurement points on drawn cup surface

for F = 1200MPa

Fig.5.5 Maximum temperature at measurement points on drawn cup surface

for F = 1500MPa g17 1 2 3 4 5 22 p d c b a / g17 1 2 3 4 5 22 p d c b a / Higher than 200

78 590 F = 1000MPa 140 160 F = 800MPa 120 44 59 F = 1200MPa F = 1500MPa 98 F Fig.5.6

Fig.5.6 Relationship between maximum temperature and plastic coefficient

M ax im um t em pe ra tu re / F value /MPa

79

5.3

0.03 0.06 0.12 0.18

Figs.5.7~5.10

0.18

Fig.5.7 Maximum temperature at measurement points on drawn cup surface for

friction coefficient = 0.03 h18 1 2 3 4 5 22 p d c b a /

80

Fig.5.8 Maximum temperature at measurement points on drawn cup surface for

friction coefficient = 0.06

Fig.5.9 Maximum temperature at measurement points on drawn cup surface for

friction coefficient = 0.12 f16 1 2 3 4 5 22 p d c b a / g17 1 2 3 4 5 22 p d c b a /

81

Fig.5.10 Maximum temperature at measurement points on drawn cup surface for

friction coefficient = 0.18 p21 a14 Fig.5.11 Fig.5.12 p21 Fig.5.13 a14 Fig.5.14 e15 1 2 3 4 5 22 p d c b a /

82

Fig.5.11 Maximum wall thickness at measurement points on drawn cup surface for

each friction coefficient

Fig.5.12 Maximum wall thickness at measurement point p21 on drawn cup surface

for each friction coefficient

Friction coefficient Friction coefficient M ax im um w al l th ic kn es s /m m M ax im um w al l t hi ck ne ss / m m

83

Fig.5.13 Maximum wall thickness at measurement point a14 on drawn cup surface

for each friction coefficient

Fig.5.14 Variations in contact pressure at measurement point a14 on drawn cup

surface for different friction coefficient = 0.03 = 0.06 = 0.12 = 0.18 M ax im um w al l t hi ck ne ss / m m Friction coefficient Punch stroke /mm C on ta ct p re ss ur e /G pa

84 5.4 Fig.5.15 g17 2.63mm g17 G G C 0. 2 mm G

85

Fig.5.16 f16

152 169 17

Fig.5.16 Maximum temperature at measurement points on drawn cup surface for a

modified die shape

5.5 FEM (1) 44 59 98 f16 1 2 3 4 5 22 p d c b a /

86 (2)

87

6

88 (3) (4) 4 3 FEM (3) (4) 5 FEM (4) 440 590 980 (5) (6) 6

90

(1) (1987) 35-36

(2) (1990) 35-36

(3) Block H. Proc. General Discussion on Lubrication and Lubricants IME 2(1937) 14-15

(4) Block H. Proc. International Conference Gearing IME (1958) 144-145

(5) 36-281(1970) 119-125 (6) 44-382(1978) 2089-2098 (7) 43-376(1977) 4670-4678 (8) 44-383(1978) 2536-2546 (9) 44-383(1978) 2547-2557 (10) 24-9(1979) 573-578 (11) 46-408(1980) 953-961 (12) 47-423(1981) 1518-1529 (13) (2001) 203-204

(14) J. L. Andreasen N. Bay and L. De Chiffre International Journal of MachineTools and Manufacture Volume 38 Issues 5-6 (1998) pp. 503-510 (15) K. P. Rao and J. J. Wei Wear Volume 249 Issues 1-2 (2001) pp.85-92 (16)

67-14(1981) 2152-2161

(17) 41-468(2000) 59-63

(18) 13-141(1972) 729-743

(19) E.P. Unksov An Engineering Theory of Plasticity (1961) 107 Butterworth.

(20) 19-204(1978)

91

(21) 17-190(1976) 867-874

(22) 47-417(1981) 644-652

(23) ADDRG Sheet Metal Industry 54(1977) 147

(24) 57 (1982) 129 (25) (1993) 23-24 (26) 2000 (27) 46-534 (2005) 585-589 (28) 46-534 (2005) 8-11 (29) 154(2013) 5-10 (30) 43-492(2002) 3-10 (31) 46-7(2001) 7 (32) 46-528(2005) 4-10 (33) (1998) (34) 46-528(2005) 11-14 (35) 421(2001) 24 (36) 39-12(2001) 24-30

92

1 Tribological peculiarity of galling position in square cup drawing (Tomoki Soejima, Mingxu Yang, Zhigang Wang and Yasuharu Yoshikawa) Key

engineering materials, Vols.535-536, pp.334-337(2013)

2 ( , ,

, ) ,

1. Galling behavior in square cup drawing of high tensile strength steel sheet, (Mingxu Yang, Zhigang Wang and Keisuke Tanabe), The 10th asia-pacific conference on engineering plasticity and its application, pp.403-407(2010), Wuhan, China. 2. , ( , ), 2011 , pp.124-125(2011), , . 3. , ( , , ), 63 , No301(2012). 4. , ( , , ), 63 , No299(2012).

5. Tribological feature of square cup drawing test, (Mingxu Yang, Zhigang Wang, Yasuharu Yoshikawa and Shunsuke Ando), American institute of physics, pp.1146-1150(2013), Shenyang, China.

6. Effect of blank shape on galling behavior in square cup drawing, (Mingxu Yang, Zhigang Wang, Yasuharu Yoshikawa and Shunsuke Ando), 16th international conference on advances in materials and processing technologies, No218(2013),

Taipei, Taiwan.

7. , ( , , ,

93