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Experimental Study on Micro Forming of Structured Surfaces for High Static Friction Connection Elements

机译：高静态摩擦连接元件结构表面微观成形的实验研究

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摘要

Bolt connections are the most prevalent technical solution to join several devices. To meet high requirements on lightweight constructions and safety-relevant technologies bolt connections require additional security elements or surface modifications to increase static friction without damaging the workpiece surface significantly. One possible solution is the micro structuring of the connection element surface within the conventional forming process chain. For the manufacturing of micro structured connection elements a micro structured forming tool is needed. Therefore, the forming tool has to feature a negative geometry of the connection element surface micro geometry. Requirements on forming tool materials are high hardness in combination with high wear resistance and good toughness. Suitable technologies to manufacture such micro structured metal dies are laser beam machining (LBM), electrochemical machining (ECM) and electrical discharge machining (EDM), respectively. In this study the micro forming process of high static friction connection elements is investigated. The manufactured connection element surfaces are analyzed after the forming experiments and the results are associated with the surfaces of the metal dies. Therefore the surfaces of the utilized metals dies are compared with each other and with a grinded reference surface and characteristic parameters are analyzed. The comparison is based on the resulting surface roughness parameters and surface conditions before and after lubricated forming experiments. At least wear of the metal dies after multiple forming operations is analyzed. As one result, ECM manufactured metal dies have shown a high degree of replication in combination with high wear resistance.
机译：螺栓连接是加入多个设备的最普遍的技术解决方案。为了满足轻量级结构和安全相关技术的高要求，螺栓连接需要额外的安全元件或表面修改，以提高静摩擦，而不会显着损坏工件表面。一种可能的解决方案是传统成形过程链内的连接元件表面的微结构。为了制造微结构化连接元件，需要微结构化成型工具。因此，成形工具必须具有连接元件表面微观几何形状的负几何形状。成型工具材料的要求与高耐磨性和良好的韧性相结合。制造这种微结构金属模具的合适技术是激光束加工（LBM），电化学加工（ECM）和电气放电加工（EDM）。在这项研究中，研究了高静电摩擦连接元件的微观成形过程。在形成实验之后分析制造的连接元件表面，结果与金属模具的表面相关联。因此，利用金属模具的表面彼此比较，并通过研磨的参考表面和特征参数进行分析。比较基于润滑成型实验前后的所得表面粗糙度参数和表面条件。在分析多重成形操作后，金属模具的至少磨损。结果，ECM制造的金属模具表达了高耐磨性的高度复制。

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