Galling phenomena in metal forming
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ISSN 2223-7690 CN 10-1237/TH
REVIEW ARTICLE
Galling phenomena in metal forming Kuniaki DOHDA1,*, Masahito YAMAMOTO1,2, Chengliang HU3,*, Laurent DUBAR4, Kornel F. EHMANN1 1
Department of Mechanical Engineering, Northwestern University, Evanston, IL 60208-3111, USA
2
Manufacturing Engineering Center, NSK Ltd., Fujisawa-Shi 251-8501, Japan
3
Institute of Forming Technology and Equipment, School of Materials and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
4
LAMIH UMR CNRS 8201, Université Polytechnique Hauts-de-France, Valenciennes Cedex 959313, France
Received: 17 March 2020 / Revised: 05 July 2020 / Accepted: 07 July 2020
© The author(s) 2020. Abstract: Galling phenomena in metal forming not only affect the quality of the engineered surfaces but also the success or failure of the manufacturing operation itself. This paper reviews the different galling conditions in sheet and bulk metal forming processes along with their evolution and the effects of temperature on galling. A group of anti-galling methods employed to prevent galling defects are also presented in detail. The techniques for quantitatively measuring galling are introduced, and the related prediction models, including friction, wear, and galling growth models, are presented to better understand the underlying phenomena. Galling phenomena in other processes similar to those occurring in metal forming are also examined to suggest different ways of further studying galling in metal forming. Finally, future research directions for the study of galling in metal forming are suggested. Keywords: galling; metal forming; friction; wear; adhesion; anti-galling
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Introduction
Galling is a phenomenon in which the frictional force abruptly increases under specific conditions at the contact surface due to microscopic welding [1, 2]. The term has been used to describe different types of surface damage that occur during practical applications in mechanical engineering systems [3–5]. Relatively limited galling can be observed in bearings and gears, for example, where it appears as scuffing or scoring on the accompanying surfaces. Galling has been recognized as a form of seizure on frictional surfaces that have become thermally or mechanically unstable [6–9]. Furthermore, several terms that attempt to describe the progress of surface damage to some extent have been proposed to describe galling, such as lubrication
failure, micro-welding, pick-up, and build-up. This article focuses on galling in metal forming. Galling phenomena between the tool and workpiece lead to a sharp increase in the forming load, fatal damage of the product surface, and severe wear of the tools. In metal forming, the mechanisms at the interface are quite complicated because the surface area increases due to bulk deformation, and the interface structure of the lubricant, oxide film, etc. greatly changes. Many factors are influencing galling, including deformation degree, tool surface roughness, lubricating film, and interface temperature [10]. Galling in metal for
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