Forming without Lubricant – Functionalized Tool Surfaces for Dry Forming Applications☆

Abstract Bulk metal forming processes –such as rotary swaging – are carried out under intense use of lubricants. The development of a dry process layout is highly desirable, both under economic and ecological aspects. In this work functionalized rotary swaging tools are introduced that exhibit a combination of hard coated and structured surfaces. These customized tool surfaces are designed to avoid adhesion effects of the workpiece material and to control process forces when dry forming. Rotary swaging experiments were carried out and the work results are discussed under the specific challenges of forming aluminum and steel workpieces.