Dynamic Die Supply: Enhancing Stamping Operations with Better Galling Detection

Galling, a prevalent issue in sheet metal stamping, poses significant challenges for manufacturers due to its detrimental effects on die surfaces and stamped parts. Unlike typical abrasive wear, galling results from the adhesion of particles separated from the sheet metal during sliding along the die surface. Detecting the onset of galling is crucial for maintaining high-quality stamped parts and preventing costly downtime associated with die maintenance.

Recent research conducted by Oakland University’s Center of Advanced Manufacturing and Materials (CAMM) offers valuable insights into galling detection during room-temperature stamping of aluminum alloy sheet AA5754, commonly used in lightweight automotive structural parts. Using the U-bend process, researchers investigated die wear behavior to develop effective detection methods.

The experimental methodology involved blanking the strip from a 2.5-mm-thick coil lubricated with 61AUS lubricant, followed by stamping the U-bend coupons in a progressive die setup. The depth of draw and inner radius of the U-bend part were carefully controlled, with variations in flange length based on clamping force, friction, and material stretching.

A schematic of the progressive die for stamping the U-bend coupons illustrates the complexity of the experimental setup. Gas springs charged from a nitrogen tank supported the blank holder, ensuring consistent pressure throughout the stamping process.

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Article with all rights reserved, courtesy of thefabricator.com

Photo with all rights reserved, courtesy of depositphotos.com