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Precise identification of friction coefficient and real-time detection and prediction of seizure in cold forging

Research Project

Project/Area Number 21K04721
Research Category

Grant-in-Aid for Scientific Research (C)

Allocation TypeMulti-year Fund
Section一般
Review Section Basic Section 26050:Material processing and microstructure control-related
Research InstitutionShizuoka University

Principal Investigator

Hayakawa Kunio  静岡大学, 工学部, 教授 (80283399)

Project Period (FY) 2021-04-01 – 2024-03-31
Project Status Completed (Fiscal Year 2023)
Budget Amount *help
¥4,160,000 (Direct Cost: ¥3,200,000、Indirect Cost: ¥960,000)
Fiscal Year 2023: ¥260,000 (Direct Cost: ¥200,000、Indirect Cost: ¥60,000)
Fiscal Year 2022: ¥520,000 (Direct Cost: ¥400,000、Indirect Cost: ¥120,000)
Fiscal Year 2021: ¥3,380,000 (Direct Cost: ¥2,600,000、Indirect Cost: ¥780,000)
Keywords冷間鍛造 / 潤滑 / 摩擦係数 / ピエゾ素子 / トライボロジー / 有限要素解析 / 鍛造 / 摩擦 / 摩耗 / 加工速度依存性 / 凝着 / 検出
Outline of Research at the Start

本研究では,「冷間鍛造における摩擦係数の高精度同定と焼付きのリアルタイム検出・予測」として,以下の研究に取り組む.
・これまでの潤滑性能評価の研究において,定量化が困難であった加工速度により変化する摩擦係数を,高精度な実験と有限要素解析により明らかにする.
・工具を拘束する圧電素子埋込みボルトにより検知される加速度信号を詳細に解析することにより,潤滑剤の欠乏により生じる焼付きなどの潤滑状態の急変をリアルタイムに検出する.さらに,信号の過渡情報を用いて,焼付き発生を予知する技術を開発する.

Outline of Final Research Achievements

In the evaluation of lubrication in cold forging, the dependence of lubrication characteristics on processing speed was evaluated. A reasonable coefficient of friction was identified using calibration curves based on a precise material model, and it was clarified that the coefficient of friction at high speed is smaller than that at low speed.
Next, a piezoelectric sensor installed in a bolt was used to detect and predict changes in lubrication conditions in real time. As a result, it was shown that the elastic deformation of the outer diameter dimension of the die occurred in response to the contact between the specimen and the die and the filling state, and that this deformation could be detected by the change in output of the bolt-type piezoelectric sensor.

Academic Significance and Societal Importance of the Research Achievements

冷間鍛造における摩擦係数の加工速度依存性の定量的評価およびそのメカニズムを明らかにできたが,このことは,潤滑剤の開発において,トライボシミュレーターが考慮すべき事柄を明確にし,また実際の潤滑剤の利用において,速度依存性の考慮に合理的な判断を与えた.
また,ピエゾ素子における摩擦係数のリアルタイム測定の可能性を明らかにしたが,このことは,今後のより高精度なトライボシミュレーターの設計や潤滑特性評価に資するものである.また,この技術は,実加工中の不具合の検出にも応用可能である.

Report

(4 results)
  • 2023 Annual Research Report   Final Research Report ( PDF )
  • 2022 Research-status Report
  • 2021 Research-status Report
  • Research Products

    (12 results)

All 2024 2023 2022 2021

All Journal Article (3 results) (of which Int'l Joint Research: 1 results,  Peer Reviewed: 3 results,  Open Access: 1 results) Presentation (9 results) (of which Int'l Joint Research: 3 results,  Invited: 2 results)

  • [Journal Article] International round robin test of environmentally benign lubricants for cold forging2023

    • Author(s)
      Volz S.、Launhardt J.、Bay N.、Hu C.、Moreau P.、Dubar L.、Nielsen C.、Hayakawa K.、Kitamura K.、Groche P.
    • Journal Title

      CIRP Annals

      Volume: 72 Issue: 1 Pages: 245-250

    • DOI

      10.1016/j.cirp.2023.03.019

    • Related Report
      2023 Annual Research Report
    • Peer Reviewed / Int'l Joint Research
  • [Journal Article] Evaluation of Tribological Characteristics of Titanium Alloy by Cold and Warm Forward Rod-Backward Can Combined Extrusion Test2022

    • Author(s)
      西 源貴 , 久保田 義弘 , 早川 邦夫 , 中村 保
    • Journal Title

      Journal of the Japan Society for Technology of Plasticity

      Volume: 63 Issue: 742 Pages: 145-150

    • DOI

      10.9773/sosei.63.145

    • ISSN
      0038-1586, 1882-0166
    • Related Report
      2022 Research-status Report
    • Peer Reviewed
  • [Journal Article] An Anisotropic Damage Model for Prediction of Ductile Fracture during Cold-Forging2022

    • Author(s)
      Atsuo Watanabe, Kunio Hayakawa and Shinichiro Fujikawa
    • Journal Title

      metals

      Volume: 12 Issue: 11 Pages: 1823-1823

    • DOI

      10.3390/met12111823

    • Related Report
      2022 Research-status Report
    • Peer Reviewed / Open Access
  • [Presentation] Electro-Thermo-Mechanical Finite Element Analysis on SPS Sintering Process of Zirconia Part2024

    • Author(s)
      Kunio Hayakawa
    • Organizer
      International Conference on Advanced Functional Materials (AFMD-2024)
    • Related Report
      2023 Annual Research Report
    • Invited
  • [Presentation] ピエゾセンサーによるチタン合金の鍛造におけるトライボロジー特性の評価2024

    • Author(s)
      指宿八洲,久保田義弘,早川邦夫
    • Organizer
      日本材料学会東海支部第18回学術講演会
    • Related Report
      2023 Annual Research Report
  • [Presentation] 金属箔材の穴あけ工程における工具摩耗の測定とせん断面の観察2023

    • Author(s)
      中根崇志,早川邦夫,鈴木英彦,呂子蒙,古澤樹
    • Organizer
      2023年度塑性加工春季講演会
    • Related Report
      2023 Annual Research Report
  • [Presentation] 難加工材料の押出しにおけるトライボロジー特性の評価2023

    • Author(s)
      早川邦夫
    • Organizer
      第352回塑性加工シンポジウム
    • Related Report
      2023 Annual Research Report
    • Invited
  • [Presentation] An Anisotropic Damage Model for Prediction of Ductile Fracture during Cold Forging2022

    • Author(s)
      Atsuo Watanabe, Kunio Hayakawa, Shinichiro Fujikawa
    • Organizer
      WCCM2022
    • Related Report
      2022 Research-status Report
    • Int'l Joint Research
  • [Presentation] 鋼材の冷間前‐後方直缶押出しにおける環境対応型潤滑剤の成形速度依存性2021

    • Author(s)
      早川邦夫,久保田義弘,高橋一平,石橋格,中村保
    • Organizer
      2021年度塑性加工春季講演会
    • Related Report
      2021 Research-status Report
  • [Presentation] チタン合金の温間前方軸‐後方缶押出しにおける酸化膜のトライボロジー特性の温度依存性2021

    • Author(s)
      西源貴,久保田義弘,早川邦夫,中村保
    • Organizer
      2021年度塑性加工春季講演会
    • Related Report
      2021 Research-status Report
  • [Presentation] Effect of production rate on lubrication performance in combined forward can - backward can cold extrusion test2021

    • Author(s)
      K. Hayakawa, I. Takahashi, Y. Kubota, T. Nakamura, I. Ishibashi
    • Organizer
      The 13th International Conference on the Technology of Plasticity (ICTP 2020)
    • Related Report
      2021 Research-status Report
    • Int'l Joint Research
  • [Presentation] Temperature Dependency of Friction of Titanium Alloy by Forward Rod-Backward Can Combined Extrusion Test2021

    • Author(s)
      G. Nishi, Y. Kubota, K. Hayakawa, T. Nakamura
    • Organizer
      International Conference on Tribology of Manufacturing Process (ICTMP2021)
    • Related Report
      2021 Research-status Report
    • Int'l Joint Research

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Published: 2021-04-28   Modified: 2025-01-30  

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