Sheet Metal Coating and Indentations for Targeted Forming Lubrication
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Solution Overview
Problem
Existing methods for producing sheet metal products through mechanical forming require excessive lubricant use, leading to increased effort and environmental concerns due to the need for constant re-wetting and potential instability in the forming process.
Innovation Solution
A method involving a coated sheet metal pre-product with rolled depressions that absorb and transport lubricant to critical areas during forming, where the coating is elastically deformable under low loads and plastically deformable under high loads, ensuring targeted and efficient lubrication without excessive lubricant use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional lubrication is used to reduce frictional forces and holding forces, then the sheet metal flow is improved, but the manufacturing complexity and cleaning effort increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-applying lubricant to the sheet metal blank before the forming process begins. The lubricant is introduced into recesses that are pre-formed on the blank surface, allowing the lubricant to be positioned in advance at critical areas rather than requiring continuous application during forming. This reduces the complexity of the lubrication system while ensuring proper lubrication where needed.
2Strength
If lubricant is continuously applied to prevent direct metallic contact, then wear is reduced, but lubricant consumption increases and process stability decreases
Solution Approach 1:
The patent implements local quality by concentrating lubricant application only at specific critical areas where high friction and wear occur during forming. Recesses are strategically positioned at these locations (such as the draw edge and flange area) to hold lubricant, rather than applying lubricant uniformly across the entire surface. This localized approach reduces overall lubricant consumption while providing adequate protection where it is most needed.
Solution Approach 2:
The patent uses a porous or textured surface structure with recesses that can absorb and retain lubricant. These recesses act as reservoirs that hold the lubricant in place and release it gradually during the forming process, reducing the need for continuous lubricant application while maintaining effective lubrication at the interface between the blank and forming tool.
3Reliability
If draw beads are used to increase holding forces, then sheet metal flow control is improved, but the frictional forces and local stresses increase
Solution Approach 1:
The patent introduces lubricant as an intermediary substance between the sheet metal blank and the forming tool, particularly at the interface where draw beads exert their holding force. The lubricant reduces the frictional component of the holding force, allowing for better sheet metal flow control with reduced local stresses. This mediates the interaction between the draw bead mechanism and the sheet metal, enabling effective flow control without excessive stress concentration.
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
This method allows for effective lubrication of critical areas during sheet metal forming, reducing lubricant consumption and maintaining process stability, while minimizing environmental impact by using less lubricant and ensuring continuous lubrication where needed.
Implementation Method 1
the coating in the forming tool is elastically deformable during the forming process, in particular under relative movement between the sheet metal and tool surface, under loads of 0.5 MPa to 20 MPa
Implementation Method 2
plastically deformable under loads above 20 MPa
Implementation Method 3
the functionality of the lubricants used is essentially determined by the additives they contain. These additives can, for example, create a boundary layer by adhering polymer chains or through chemical reactions on the metallic surfaces
Implementation Method 4
The bond between the polymer chains is based on van der Waals forces, allowing them to slide relatively easily against each other
Implementation Method 5
the bond between the polymer chains and the surfaces of the forming tool and the sheet metal preform is based on a dipole bond
Data Source
Figure 1~3
AI summary
The invention relates to a method for producing a sheet metal product (1) from a sheet metal blank (2), wherein: at least one surface (7) of the sheet metal blank (2) is coated with a coating; the sheet metal blank (2) is rolled; during rolling, depressions (6) are rolled into the surface (7); after coating and rolling, lubricant (8.1) is introduced into the depressions (6); after the lubricant (8.1) has been introduced, the sheet metal blank (2) is mechanically shaped with a shaping die (5), characterized in that the surface (7) is coated in such a manner that the coating is elastically deformable under loads of 0.5 MPa to 20 MPa and is plastically deformable under loads above 20 MPa in the shaping die (5) during the shaping process, particularly under relative movement between sheet and tool surfaces.