Environmentally friendly lubricants and processes for the cold/hot forging industry

1. College of Engineering Center for Excellence in Forging Technology, I WSE Department 210 Baker Systems, 1971 Neil Avenue, Columbus OH 43210-1271 Environmentally friendly lubricants and processes for the cold/hot forging industry Chun Liu, Minhao Cai, Yuanjie Wu, Ling Yang, Sridhar Srivatsan,Research Associate Steven Z.Q. Sheng, Sailesh Babu, Guowen Tan, Jun Qi, D.K. Min Post Doctoral Researcher Rajiv Shivpuri, Professor and Director

2. Outline of the Presentation 1. Introduction 2. Objectives 3. Friction Module for Cold/Hot Forging 4. Fluid Module for Lubricant Spray 5. Optimization on Lubricant Spray 6. Current Progress and Future Works

3. Introduction • Insufficient Lubricant: High energy, High tooling wear, Poor filling and workpiece surface quality, Lower formability. • Excessive Lubricant : Environmental pollution, die failure, damage to electrical systems, damage to workpiece surface quality.

4. Objectives • To develop a graphite free lubricant for hot forging • To develop a friction module for Hot/Cold forging simulation • To develop a fluid spray module for lubricant spray process in the Hot/Cold forging simulation. • To develop an optimal control on the lubricant spray process

5. A Fluid Module for Lubricant Spray in Hot/Cold Forging Simulation By Lin Yang, Z.Q.Sheng

6. Die Modeling Components 2. Heat Transfer 1. Plume 3. Deposition 4. Pollution

7. 0.6 0.4 0.2 0.0 1.0 0.8 0.6 1.0 0.4 0.8 0.6 0.2 0.4 0.2 0.0 0.0 ModelingSpray Process Multi-Droplet Modeling Single Droplet Modeling Deposition Pattern and Thickness Distribution

8. A Friction Module for Hot/Cold Forging Simulation By Minghao Cai, Yuanjie Wu, Sridhar Srivatsan and D.K. Min

9. Definition of Friction [Steven R. Schmid,2002] h is the average film thickness are the roughness of the workpiece and tooling Ht > 10, thick film lubrication; , thin film lubrication; , mixed film regime; , boundary lubrication.

10. Model Friction and Heat Transfer Define Initial Lubrication Status Calculation of Variation of Film thickness, Surface roughness, Viscosity, Contact area Calculation of Variation of Friction Coefficient and Heat transfer during forging

11. Verification by Compressive Ring Test

12. Verification by Spike Test

13. Verification by Backward Extrusion

14. Optimization on Lubrication Spray Process By Chun Liu, Lin Yang and Steven Sheng

15. Optimization Model Design Variables: lubricant pressure p, speed of nozzle movement v, angle of nozzle γ, ratio between lubricant components (such as water and graphite) λ, distance between nozzle and tooling surfaces d, Objective Function: lubricant spray into the air; Lubricant deposited on the die surfaces. Strategy: Minimizeby choosing a X

16. Optimization Control on Lubricant Spray Process (Cutesy of Acheson)

17. Progress and Future Works • Ring Test onFlat die (by Srivatsan) Instrumented die Ring Test for Lubrication Evaluation

18. Progress and Future Works • WearDie for Wear Test (by Chun Liu)

19. Progress and Future Works • Backward Extrusion Die (by Minghao Cai)

20. Progress and Future Works • Spike Die (by Yuanjie Wu)

21. Progress and Future Works • Test Stand for Lubricant Spray Process (by Lin Yang) Up/Bottom Dies

22. Progress and Future Works • To be done: • Friction and heat transfer model in the Hot/Cold forging simulation; • Fluid dynamic model for lubricant spray in the Hot/Cold forging; • Optimization on the lubrication spray process.

23. Questions !!!