Micro-Structured Lubrication for Fine Blanking Tool Wear
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Solution Overview
Problem
Fine blanking of thicker parts with complex geometries faces challenges due to insufficient lubrication, leading to wear and cold welding issues, which limits the reliability and efficiency of the process.
Innovation Solution
A method and device that adjust the cutting oil film thickness based on workpiece thickness, material, and geometry, using a micro-surface structure on functional surfaces to ensure even distribution and supply of cutting oil to the forming zone through controlled pressure, preventing oil film tear-off and enhancing lubrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional oil supply method is used, then the lubrication is simple, but the cutting oil cannot reach the forming zone sufficiently, leading to inadequate lubrication
Solution Approach 1:
The lubrication system is segmented into multiple independent oil supply channels, each targeting specific active joints and surfaces. The cutting oil is divided into multiple subsets that are supplied through different pathways (channels in punch, ejector, and inner forming punch) to ensure comprehensive coverage of all friction zones, including the critical forming zone that was previously inaccessible.
Solution Approach 2:
Functional surfaces with micro-surface structures (indentations, dimples, or bores) are introduced as intermediaries to store and distribute cutting oil. These micro-structures act as oil reservoirs that release lubricant directly at the contact interfaces, ensuring the oil reaches the forming zone through the interaction of moving functional surfaces rather than relying on direct pressure supply alone.
2Reliability
If the cutting oil film is made thicker to ensure sufficient lubrication, then the lubrication coverage is improved, but the oil film tears off during cutting
Solution Approach 1:
Instead of applying a uniform thick oil film across all surfaces, the system provides locally optimized lubrication. Micro-surface structures are created only on functional surfaces that require enhanced lubrication, and cutting oil is supplied selectively to specific active joints through dedicated channels. This localized approach ensures sufficient oil coverage where needed while preventing excessive oil accumulation that would cause film instability and tear-off.
Solution Approach 2:
Functional surfaces are equipped with micro-surface structures (indentations, dimples, or bores) that create a porous-like oil storage capacity. These micro-structures hold cutting oil and release it gradually during the cutting cycle, maintaining a stable, controlled oil film thickness that prevents both insufficient lubrication and excessive oil that would tear off. The micro-structures effectively regulate oil delivery to match the actual lubrication needs.
3Reliability
If more cutting oil is supplied to thicker workpieces, then the lubrication of thick parts is improved, but the oil consumption increases and control becomes more difficult
Solution Approach 1:
The lubrication system is designed to be dynamically adaptable to different workpiece thicknesses, materials, and geometries. Oil supply quantities and pressures are adjusted based on the specific workpiece characteristics. The system can switch between different lubrication modes (e.g., relying more on micro-surface stored oil for thinner parts vs. utilizing pressure-fed oil through channels for thicker parts) to optimize performance across a range of conditions without requiring complete process redesign.
Solution Approach 2:
The system controls lubrication by adjusting key parameters including oil pressure, oil flow rate, and micro-surface structure geometry (depth, density, distribution) based on workpiece thickness, material type, and geometric complexity. For thicker parts, higher oil pressure and greater micro-surface oil storage capacity are employed. For thinner parts, lower pressure and reduced oil storage suffice. This parameter-based control enables reliable fine blanking across varying workpiece specifications while preventing excessive oil consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable and precise fine blanking of parts thicker than 5 mm, significantly reducing tool wear and cold welding, thereby extending tool service life and improving process reliability.
Implementation Method 1
a first subset of the stored cutting oil being taken from a functional surface of the cutting punch and the micro-surface structure introduced into the cutting plate is stored and, in the interaction of functional surfaces moving past one another, is evenly distributed on the functional surfaces to form a quasi-stationary cutting oil film
Implementation Method 2
a second subset of cutting oil is transported via the respective active joints to the active surfaces of the cutting punch and workpiece in the forming zone
Data Source
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AI summary
The invention relates to a method and a device for lubricating a tool and workpiece during cutting and forming from a strip of material. The aim is to produce parts with large wall thicknesses reliably and to a high quality, while simultaneously increasing tool life by lubricating the active surfaces up to the forming zone, in a reproducible and economical manner, without the supplied lubricant film breaking down. For this purpose, a quantity of the stored cutting oil is stored by a micro-surface structure incorporated into a functional surface of the cutting punch and cutting plate. Through the interaction of the moving functional surfaces, this oil is distributed evenly across the functional surfaces to form a quasi-stationary cutting oil film when the tool is closed. A quantity of the stored cutting oil is then transported via the respective interfaces to the active surfaces of the cutting punch and workpiece in the forming zone.