Development of deterministic-stochastic surface structures to improve the tribological conditions of sheet forming processes

Abstract In sheet-forming processes with mixed frictional state the tribological system is characterized to a great extent by the sheet-surface structure. This structure has the functions of storage, transport, and distribution of the lubricant , and take-up and transport of surface-abrasion particles . These functional characteristics are achieved by different of surface structure, the so-called stochastic and deterministic structures. The presence of micro channels connecting the surface pockets in stochastic structures allows the distribution of the lubricant in all directions but it is not possible to detain this lubricant in areas under high pressure, it simply flows aside. This ability is given by the isolated surface pockets ( hydrostatic lubrication pockets ) in deterministic structures. From this micro reservoirs the lubricant can be transported directly into the deformation zone by means of building up a hydrostatic pressure. However, because of the absence of micro channels it is not possible to transport the lubricant to all areas of micro contact between tool and sheet, the risk of cold-welding effects increases. Therefore, a new type of surface structure is developed by the combination of a deterministic and a stochastic sheet-surface structure. The results of strip-drawing experiments point out that the combination between isolated lubrication pockets and a network of micro channels to transport the lubricant in the space between these surface pockets leads to a improvement of the forming behaviour.