TR73

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B4 - DLC Coatings for Forming Tools



Tribological DLC Coatings in Combination with Surface Texturing for Forming Tools to Increase Lifetime and to Improve Process Quality

Project Status: Active

Last Update: 18.02.2019



Members


In the second phase of TCRC 73, it was shown that, in sheet bulk metal forming (SBMF), tungsten-modified hydrogenated amorphous carbon coatings can affect friction between tool and workpiece. Methods of design of experiment were used to identify the impact of parameters of the coating process on the coatings’ mechanical properties and tribological behavior. The findings were used to predict and adjust the coatings’ properties. Furthermore, masking and ablation techniques were used to combine coatings with different tribological behavior on the same surface, allowing a local adaption of tribological conditions in sheet-bulk metal forming processes.

B4 Ziel en

Fig. 1: Illustration of a BMU tool with different tribological regions, realized by a combination of local coating and surface microtextures.

In the third phase, the coatings‘ contribution to an extension of the tool’s lifetime will be analyzed. Therefore, the coatings’ fatigue life and wear resistance will be examined and finally improved by adaption of the coatings’ architectures. Moreover, high-energetic deposition of adhesion layers and adjustment of stress in the substrate material can affect the coatings’ adhesion and wear resistance. Additional subsequent mechanical treatment will be used to reduce the roughness of coated surfaces. To ensure an individual lifetime of DLC-coated components, a carbon-based sensor coating is being developed. Research comprises the development of appropriate coating architectures, electrical bonding as well as electrical, mechanical and tribological characterization. Furthermore, a-C:H:W coatings will still be used to improve die filling in sheet-bulk metal forming processes. Therefore, a-C:H:W coatings will be combined with surface modifications developed within the TCRC 73. The coatings’ wear resistance under real test conditions and the coatings’ impact on die filling of functional parts of manufactured components will be investigated by geometric measurements and in component test rigs, respectively.

Fig. 2: Vision of a SBMF tool, locally coated with carbon-based sesor coatings.


Working Groups


Publications

    2020

    • Weikert, T.; Tremmel, S.; Stangier, D.; Tillmann, W.; Krebs, E.; Biermann, D.: Tribological studies on multi-coated forming tools. In: Journal of Manufacturing Processes, 49(2020), pp. 141-152

    2019

    • Marian, M.; Weikert, T.; Tremmel, S.: Numerical and Experimental Studies on Friction Reduction by Surface Modification in TEHL Contacts. In: 74th STLE Annual Meeting & Exhibition (Nashville, Tennessee, 19. Mai 2019 - 23. Mai 2019), (2019), pp. 1-n
    • Weikert, T.; Tremmel, S.: Dünnschichtsensoren zur Verschleißdetektion als Beitrag zur Auslegung intelligenter Werkzeuge – eine Machbarkeitsstudie. In: 4. Industriekolloquium Blechmassivumformung 2019 - DFG Transregio 73 (Hannover, 12.03.2019), (2019), pp. 1-n

    2018

    • Weikert, T.; Tremmel, S.: Wear Detection using Carbon-Based Sensor Coatings – a novel approach. In: The 18th Nordic Symposium on Tribology – NORDTRIB 2018 (Uppsala, 06/18/18 - 06/21/18), (2018), pp. 1-n

    Presentations

      2019

      • 12.03.2019: Weikert, T.: Dünnschichtsensoren zur Verschleißdetektion als Beitrag zur Auslegung intelligenter Werkzeuge – eine Machbarkeitsstudie, 4. Industriekolloquium Blechmassivumformung 2019 - DFG Transregio 73 (Hannover, 12.03.2019)
      • 23.05.2019: Marian, M.: Numerical and Experimental Studies on Friction Reduction by Surface Modification in TEHL Contacts, 74th STLE Annual Meeting & Exhibition (Nashville, Tennessee, 19. Mai 2019 - 23. Mai 2019)

      2018

      • 20.06.2018: Weikert, T.: Wear Detection using Carbon-Based Sensor Coatings – a novel approach, Uppsala, Schweden