Tool optimization for dry forming applications

In today's industry, waste prevention and an efficient use of resources is becoming more important due to economic and environmental requirements. Especially in forming processes such as deep drawing, a reduced use of lubricants can be highly promising in saving resources and reducing production costs. Ultimately, the highest savings can be realized by a complete lubricant free deep drawing process - namely dry forming. In this paper, an approach for lubricant-free forming by means of a protective coating and micro-structuring of the tool is presented. The work focuses mainly on the tool optimization to improve its frictional and wear properties. It is shown that ta-C coated tools can reduce friction up to 15% compared to the lubricated case. Moreover, it is outlined that a micro-structuring of the tool by Direct Laser Interference Patterning technology can reduce the tool wear.