Open Access
Influence of friction coefficient on the performance of cold forming tools
(MDPI, 2023) Barba Areso, Eneko; Salcedo Pérez, Daniel; Claver Alba, Adrián; Luri Irigoyen, Rodrigo; García Lorente, José Antonio; Ingeniería; Ingeniaritza
The automotive industry has undergone significant advancements and changes over time, resulting in the use of more complex parts in modern vehicles. As a consequence, the parts used in the manufacturing process are subject to higher stress levels, which reduce their service life. To mitigate this issue, surface treatments can be applied to improve the mechanical properties of the tools. In this study, we examined the impact of surface treatments on reducing tool stress during a cold forming process. The process involved reducing the thickness of a sheet from 6 mm to 2.5 mm, which generated high stresses in the tooling. We used finite element stress calculations to analyze the process and found that by reducing the friction coefficient to 0.1, tool stresses can be reduced by 20%, leading to an increase in tool life. Moreover, the press force and tool wear were also reduced by 18%. To validate the theoretical calculations, we performed field tests in a real manufacturing process.
Open Access
Estudio comparativo de las propiedades tribomecánicas de recubrimientos DLC depositados mediante HIPMINS con pulsos positivos sobre aceros herramientas
(2020) Claver Alba, Adrián; García Lorente, José Antonio; Escuela Técnica Superior de Ingeniería Industrial, Informática y de Telecomunicación; Industria, Informatika eta Telekomunikazio Ingeniaritzako Goi Mailako Eskola Teknikoa
Los recubrimientos DLC(Diamond Like Carbon)tienen gran importancia en la actualidad gracias a que combinan excelentes propiedades; como una dureza relativamente alta y coeficiente de fricción muy bajo, con la posibilidad de personalizar las propiedades utilizando elementos dopantes como Cr, W, Si o H entre otros en su composición. Uno de los problemas de este tipo de recubrimientos es que su adherencia no es tan buena como la de otros recubrimientos PVD. En este estudio se analizarán las propiedades tribomecánicas (adhesión, nanodureza, resistenciaal desgaste...) de recubrimientos DLC mediante el empleo del innovadorsistema de HIPIMScon pulsos positivos depositados sobre diferentes aceros herramienta. Este sistema mejora la adherencia de los recubrimientos con el substrato; aumentando así su interés industrial. Por tanto, el trabajo se centrará en la realización, análisis y comparación de los resultados de ensayos de nanoindentación, scratch test, fricción y desgaste.Los ensayos se llevaron a cabo sobre 3 aceros herramienta; vanadis-4, vancron yK-360, recubiertos con los DLC ta-Cy WC:C. Los aceros seleccionados son de gran interés por su aplicabilidad industrial y los recubrimientos mejoran considerablemente las propiedades tribológicas y la dureza superficial.Los resultadosobtenidos de los ensayos han mostrado un extraordinario comportamiento tribológico y mecánico de los recubrimientos; con valores de carga crítica LC3 en el scratch test superiores a los 70 N en alguno de los casos, durezas de entre 15 y 27 GPa dependiendo del recubrimientoy valores muy bajos de resistencia al desgaste en todos ellos.
Open Access
Study and optimization of the punching process of steel using the Johnson-Cook damage model
(MDPI, 2024) Claver Alba, Adrián; Hernández Acosta, Andrea; Barba Areso, Eneko; Fuertes Bonel, Juan Pablo; Torres Salcedo, Alexia; García Lorente, José Antonio; Luri Irigoyen, Rodrigo; Salcedo Pérez, Daniel; Ingeniería; Ingeniaritza; Institute for Advanced Materials and Mathematics - INAMAT2
Sheet metal forming processes are widely used in applications such as those in the automotive or aerospace industries. Among them, punching is of great interest due to its high productivity and low operating cost. However, it is necessary to optimize these processes and adjust their parameters, such as clearance, shear force or tool geometry, to obtain the best finishes and minimize crack generation. Thus, the main objective of this research work is to optimize the punching process to achieve parts that do not require subsequent processes, such as deburring, by controlling the properties of the starting materials and with the help of tools such as design of experiments and simulations. In the present study, tensile tests were performed on three steels with different compositions and three sample geometries. The information obtained from these tests has allowed us to determine the parameters of the Johnson-Cook damage criteria. Moreover, punching was performed on real parts and compared with simulations to analyze the percentage of burnish surface. The results obtained show that the methodology used was correct and that it can be extrapolated to other types of die-cutting processes by reducing the percentage of surface fractures and predicting the appearance of cracks. Furthermore, it was observed that clearance has a greater influence than processing speed, while the minimum percentage of the burnish area was observed for the minimum values of clearance.

Claver Alba, Adrián

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