Graded Structured Tools for Dry Rotary Swaging

Nowadays cold forming processes, especially the incremental process rotary swaging, use high amounts of lubricants with disadvantages like costs of recycling, replacement and for cleaning of the workpieces. But the lubricant fulfill necessary functions such as lubricating, flushing and cleaning of the tools. To enable dry forming without lubricant, it is necessary to substitute the functions by means of coating and structuring of the tools. In this study infeed rotary swaging with graded structured tools is investigated by FEM simulations and by experiments. The simulated process forces are in good accordance to the measured ones. Finally, the racticability of dry rotary swaging with graded structured tools is demonstrated.