The influence of self-lubricating coating during incremental sheet forming of TA1 sheet
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ORIGINAL ARTICLE
The influence of self-lubricating coating during incremental sheet forming of TA1 sheet Changxu Xu 1 & Yanle Li 1,2 & Zijian Wang 1 & Zinan Cheng 1 & Fuyuan Liu 1 Received: 8 February 2020 / Accepted: 28 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Incremental sheet forming (ISF) is an advanced sheet forming process featured with great flexibility, enhanced formability, and high efficiency especially for small batch production. However, the poor surface finish and the large forming load are the main shortages of ISF, especially for the difficult-to-form materials such as titanium sheets. In the present work, a self-lubricating coating was successfully prepared on pure titanium substrates by the atmospheric plasma spraying (APS) process before the forming process for improving the lubrication condition. It was found that the friction is significantly reduced during the forming process when using the self-lubricating coating compared with that with traditional mineral oil as the lubricant. In addition, the wear rate suggests that components’ surface has self-lubrication coating after forming due to excellent wear resistance of the coating. Furthermore, a better external surface quality can be obtained when the friction resistance is lower since the friction plays a crucial role in material deformation. The tensile test suggests that the effect of heating on sheet mechanical properties is opposite to coating on that. Finally, the effects of coating on mechanical properties of the TA1 sheet were investigated and the appropriate parameters for spraying the self-lubricating coating were determined. The present work provides a novel method for enhancing the product quality in ISF through lubrication condition improvement. Keywords Incremental sheet forming . Self-lubricating coating . Friction force . Surface finish . Atmospheric plasma spraying
Abbreviations ISF Incremental sheet forming APS Atmospheric plasma spraying PEO Plasma electrolytic oxidation CGDS Cold gas dynamic spray TA1 Pure titanium Md Mass of deposited powder on sheet (g) Mp Total amount mass of powder delivered on the sheet (g) Rup Utilization rate of the powder Mb Mass of coated sheet before forming (g) Ma Mass of coated sheet after forming (g) * Yanle Li [email protected] 1
Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan 250061, China
2
National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan 250061, China
Md Rmw Ffd Fvd Fx Fy F1 F2 F3 F4 F4y F2x Fz μ Sa Sku Q F V t
The mass of coating within the deformation zone (g) The wear rate of coating Forming force on feed direction (N) Forming force acting vertically to feed direction (N) Forming fore in X direction (N) Forming force in Y direction (N) Vertical forming force in ZX plane (N) Resistance of material deformation (N) Vertical forming force in ZY plane (N) Reactive force of inclined wal
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