Galling Generation Mechanism in Upsetting-Ball Ironing Test

Abstract

An upsetting-ball ironing test has been developed to investigate the lubricating performance of coatings in multi-stage cold forging. By using this test, the lubricating performance of a zinc phosphate free coating called “dry in-place coating” was evaluated and improved, and now the dry in-place coating is used worldwide due to its high anti-galling ability and low environmental impact. In this study, galling generation mechanism in the upsetting-ball ironing test is investigated by using the point tracking function in FEM simulation. Scratches on ironed surface are generated at the starting point of ironing and the width and depth of scratches increase gradually with the increasing ironing stroke. It is revealed that all points on a scratch have been in contact with the same point of the ball. The lubrication coating on the billet surface peels off locally with the onset of ironing and some contamination particles enter the interface between the billet and the ball and thus cause scratches. Galling takes place at the ironing stroke of around 10 mm when the billet of 14 mm in diameter and 32 mm in height is upset to 45 percent reduction in height and then ironed by the ball of 10 mm in diameter. It is found that all points on the ironed surface at the starting position of galling are not on the initial billet surface but come from the inside of the billet. These points come out at the ironing stroke of 4 mm due to the dividing flow in the surface layer. It is concluded that galling in the upsetting-ball ironing test is generated by the extremely large surface expansion.