1 Research position in Sheet Metal Forming Tribology in Denmark | Technical University of Denmark (DTU)

The project aims at finding environmentally benign tribo-systems for sheet metal stamping of difficult materials such as advanced high strength steels, stainless steels, Al- and Ti-alloys, in order to replace present, environmentally hazardous lubricants. An off-line procedure for evaluation of new tribo-systems is to be developed based on a new, custom built PC/PLC controlled sheet-tribo-tester and a procedure including numerical analysis of the production process to select appropriate laboratory test parameters, which emulates the production conditions. Fundamental analysis of liquid lubrication in sheet stamping including influence of tailored tool surface topographies facilitating micro-hydrodynamic lubrication will form basis for improving limits of lubrication of environmentally acceptable lubricants developed and tested together with leading manufacturers. New tool coatings e.g. pure diamond, which impedes galling, will be tested.

Stamping of sheet metal by deep drawing, ironing and punching in tribologically difficult materials such as advanced high strength steel (AHSS), stainless steel, aluminium alloys and titanium alloys requires very efficient tribo-systems. It is often necessary to apply environmentally hazardous lubricants such as chlorinated paraffin oils to avoid lubricant film breakdown and galling, which lead to poor surface quality of formed components and eventually production stop. During the last decade legislation in Europe and Japan has been increasingly restrictive with respect to the industrial application of such lubricants and many sheet stamping industries are struggling to find alternative, environmentally benign lubricants. Testing of possible alternatives in the production line is, however, costly and problematic, due to the necessary production stops, cleaning of tools before introducing the new test lubricant, as well as production stops caused by possible lubricant film breakdown and pick-up of workpiece material on polished tool surfaces, which requires dismounting and repolishing of tools. The present project addresses the above mentioned problems via three lines of approach:

• Fundamental research on analysis and modelling of liquid lubrication mechanisms
• Development of methodology for off-line evaluation of performance of new tribo-systems
• Development and testing of new tribo-systems

Qualifications:

Candidates must hold a PhD degree or similar. Further qualifications:

• Metal forming
• Numerical modelling of large plastic deformations
• Tribology
• Numerical modelling of fluid flow
• Experimental analysis
• Self-motivation in scientific research
• Ability to work independently, to plan and carry out complicated tasks
• Good communication skills in English, both written and spoken