Force-displacement motions of a lubricated and dry tapering process of an AlMgSi1 alloy

Lubricants are commonly used in metal forming to reduce friction between work piece and forming tool, to protect semi-finished products and goods against corrosion and to reduce tool load. According to the aim of environment friendly production technologies it is strived to realize dry forming by the absence of lubricants. In this study tapering of aluminium rods of an AlMgSi1 alloy with a tungsten carbide forming die is investigated. The diameter is tapered from 9.25 mm to 9.00 mm. The tapering investigations were performed lubricated as well as dry. The lubricated forming investigations showed a mean maximum press force of 5.4 kN /- 1.5 kN. The dry tapering investigations of aluminium alloys were stopped after two samples, due to aluminium adhesion in the forming zone, which prohibited tapering of more samples. Dry tapering processes lead to adhesion of aluminium in the deformation zone very quickly by the use of a tungsten carbide forming die, which prevents the tapering of a high quantity of aluminium rods.