A study of mechanisms of liquid lubrication in metal forming

Applying a transparent tool technique the lubrication in plane strip drawing of aluminium sheet is studied providing the strip with surface pockets for entrapment of lubricant. The compression and eventual escape of trapped lubricant by Micro Plasto HydroDynamic Lubrication (MPHDL) as well as Micro Plasto HydroStatic Lubrication (MPHSL) is observed and quantified experimentally with varying lubricant viscosity, drawing speed, reduction, die angle, back tension, workpiece material and friction conditions. All these parameters are shown to influence the mechanisms of lubricant escape in an explicable way. Theoretical models for the two observed mechanisms of lubricant escape, i.e. backward escape by MPHDL and forward escape by MPHSL are established combining a continuum mechanic analysis of the pressure distribution in the tool/workpiece interface with fluid mechanic analyses of the lubricant escape. Experimental observations of oscillations in the drawing force are quantitatively shown to be caused by the two mechanisms of lubricant escape.