In-situ observation of lubricant flow on laser textured die surface in sheet metal forming

Abstract In the present study, to observe the contact interface during sheet metal forming process, in-situ observation system using transparent silica glass dies and high speed recording camera was developed. To correlate the dimensional parameters of micro-textured structures and tribological properties during the forming operation, in-situ observation during ironing process of stainless steel sheet with a thickness of 0.1 mm was performed. Tribological behavior was compared between the different dimple structures under different contact state. Dimple structure arrays with diameters of 10, 50, 100 µm were achieved by using femto-/pico-second laser processing. As results, the textured die with dimple diameters of 10 and 50 µm showed the lubricant flow transferred from one to the other dimple structures, in which hydrodynamic pressure seems to generate inside the dimples, while that of 100 µm indicated the less supply of lubricant. However, for the textured die with a dimple diameter of 10 µm demonstrated higher ironing force than that of 50 µm, due to the coverage of dimple structures by generated wear debris during the forming process. Based on these experimental findings between different contact states, the principle in generation of hydrodynamic pressure, the function of micro-trap for wear debris and the micro-reservoirs effect for lubricant retention depending on the size of dimple structures were discussed by correlating with the in-situ observation results.