Digitally enhanced development of customised lubricant: Experimental and modelling studies of lubricant performance for hot stamping
提出一种数字化增强的润滑剂开发方案，结合机制交互摩擦建模和数据驱动的润滑剂极限图，通过案例开发定制热冲压润滑剂，经工业验证性能优异，可提升优化效率并降低试验成本。
Digitally enhanced technologies are transforming every aspect of the manufacturing sector towards the era of digital manufacturing. Traditional lubricant development methods involving systematic but time-consuming iterative processes is still extensively used in the metal forming industry. In the present study, a novel digitally enhanced lubricant development scheme was proposed by leveraging a mechanism-based interactive friction modelling framework and quantitative and comprehensive evaluation of lubricant performance via the data-centric lubricant limit diagrams. By predicting transient lubricant behaviour following the complex contact condition evolution experienced in actual forming operations, a close association and quantified relation between the lubricant performance and its properties such as viscosity, evaporation rate and fraction of dry matter was established. This can facilitate the optimisation efficiency of lubricant parameters and minimise the experimental cost for iterative lubricant trials. A case study was conducted in this work to develop a customised lubricant using this digitally enhance scheme for the target hot stamping process based on a benchmark lubricant as a reference. Further industrial forming tests of an automotive component were conducted to validate the ideal performance of the customised lubricant. • A digitally enhanced lubricant development scheme incorporating interactive modelling and data-centric evaluation via LLD. • This scheme enables intuitive illustration and quantitative evaluation of lubricity emulating actual complex conditions. • The scheme can facilitate optimisation efficiency and minimise the experimental cost for iterative lubricant trials. • A customised lubricant for hot stamping was developed following the digitally enhanced analysis with OPG value of 98.5 %.