7th International Conference on Tribology in Manufacturing Processes

February 28 to March 2, 2016

Phuket, Thailand

ICTMP 2016

International Research Group of Tribology in Manufacturing (IRGTM) in collaborations with Thai Tribology Association (TTA), National Metal and Materials Technology Center (MTEC), King Mongkut's University of Technology Thonburi (KMUTT), and Khon Kaen University (KKU) are organizing the 7th International Conference on Tribology in Manufacturing Processes (ICTMP) during February 28 to March 2, 2016 in Phuket, Thailand.

The aim of the conference is to present the latest developments in the research of tribological aspects in manufacturing processes, particularly in the following topics:

  • Tribology in forming processes
  • Tribology in cutting and finishing processes
  • Tribology in joining processes
  • Functional surfaces
  • Advanced (nano/bio) tribology

The scope of interest is related to friction, lubrication, wear, surface engineering, process modelling, applied plasticity and environmental issues. In this conference, we are strongly interested in "Tribology of Tool Materials and Designs for High Performance and Extended Service Life". Focused tool applications are (but not limited to):

  • Extrusion
  • Forging
  • Machining
  • Stamping

The applications can range from nano scale, to micro/meso scale, to macro scale. In addition, the presentations include practical guidelines for solving tribological problems in an industrial environment.

The conference will be held at Mövenpick Resort & Spa Karon Beach Phuket, Thailand from Sunday February 28 to Wednesday March 2, 2016.

Please note that all the accepted articles will be published in the Proceedings of ICTMP 2016 (ISBN: 978-616-92565-0-2)

Keynote Speakers

Prof. Peter Groche

  • Dean of the Department of Mechanical Engineering, Technische Universität Darmstadt, Germany
  • Professor (C4) for Production Engineering and Forming Machines, Technische Universität Darmstadt, Germany
  • Fellow of the International Academy for Production Engineering (CIRP)
  • Fellow of the National Academy of Science and Engineering (acatech)
  • Member of the International Cold Forging Group (ICFG)
  • Member of the German Academic Society for Production Engineering (WGP)
  • Member of the German Working Group Forming Technology (Arbeitsgemeinschaft Umformtechnik)

Keynote Title: "Tool Wear in Modern Cold Sheet Metal Forming and Its Counter Measures"

The use of advanced high strength steels in the automotive industry causes the need for an optimization of forming tools in terms of friction and wear properties of their surfaces. The present work shows, how so-called wear resistance characteristics can be determined on the base of an experimental wear test. These characteristics demonstrate the relationship between stress and tool life and improve the evaluation of wear behavior. Furthermore, a mechanical surface treatment technology called machine hammer peening is introduced which allows producing tailored tool surfaces with lubricant pockets. An overview is given on how these micro-textures reduce the coefficient of friction and influence the wear behavior in deep drawing.

Prof. Yoshinari Tsuchiya

  • Professor of Gifu University Composite Materials Center, Japan
  • Researcher of Toyota Central R&D Labs., Inc., Japan
  • Member of The Japan Society for Technology of Plasticity
  • Member of The Iron and Steel Institute of Japan
  • Member of Japanese Society of Tribologists

Keynote Title: "Tribo-Characteristics of Thin Hard Coatings and Some Considerations in Applying Them to Metal Forming Die"

Technical evolution of metal forming in Japan owes much to needs of automotive industry which wants to produce complex high-precision parts at low cost, and owes much to seeds developments of technologies such as die design, lubrication, die materials including surface coatings which attempted to meet the needs. This lecture starts with an overview of the history of metal forming technologies in Japan with the history of activities of JSTP and research subjects on die materials and surface coatings.

The following are typical views about the coatings applied to metal forming die; coating methods and characteristics in film formation. Tribo-characteristics of the coatings are summarized and it is shown that those of hard coatings or ceramic coatings are superior to those of other conventional coatings such as nitriding and carburizing. Following points, however, need to be noted when the coatings are applied to manufacturing dies; to provide dies having a smoothly-finished surface and having a base metal with large hardness. Some research data on these effects on tribo-characteristics are shown.

In addition, practical coating examples for various types of metal forming dies are shown. Large improvement effect of coatings on increasing service life time of die is obtained to prevent wear and galling under severe conditions of forging.

Finally, challenges and development trend of recent hard coating and the future expectations are summarized.

Prof. Tatsuhiko Aizawa

  • Professor and Director of Shibaura Institute of Technology, Japan
  • Professor of University of Toronto, Canada
  • Professor of University of Technology, Malaysia
  • Professor of University of Brawijaya, Indonesia
  • Academic Coordinator for Japan Die and Mold Association
  • Chairman of Die and Mold Division, Japan Society of Technology of Plasticity

Keynote Title: "Tribological Engineering and Design in Surface Treatment for Semi-Dry and Dry Stamping"

Semi-dry and dry manufacturing became a key technology toward significant reduction of environmental burden in industries. Under the minimum quantity lubrication, the tools and dies often had a risk to suffer from severe friction and wear. Four surface treatment methods were proposed to understand the perspective of tribological design and engineering for semi-dry stamping; e.g., the hard coating, the plasma nitriding, the Duplex method and the micro-texturing. Among these four methods, two methods were explained to discuss their characteristics in tribology. In particular, their role in semi-dry stamping process is discussed to aim at their applications to industries.

Assoc.Prof. Gracious Ngaile

  • Department of Mechanical and Aerospace Engineering, North Carolina State University, USA
  • Associate Editor of ASME Journal of Manufacturing Science and Engineering
  • Associate Editor of SME Journal of Manufacturing Processes
  • Guest Editor of ASME Journal of Micro and Nano Manufacturing
  • Member of ASM Tribology Division Development Committee

Keynote Title: "Tribology in Tube Forming"

In Tube Hydroforming (THF) process, the interface friction between the die and tubular blank is constantly varying in time and space due to change in the process loading path (fluid pressure vs feed). Thus, better understanding of the tribological performance is critical for the success of the THF process. This paper presents lubrication mechanisms that can be encountered in feed-driven and expansion-driven THF processes. Recent strategies used in the development of THF lubricants and evaluation techniques are discussed. The lubricant evaluation methods are presented with focus on the state of stress induced at the tube-die interface and how they can be correlated with actual THF processes. The paper also highlights the impact of numerical modeling in tube hydroforming tribology. A case study on friction error compensation scheme is presented where a database containing computer generated field variables is linked to a THF system such that friction depended loading paths can be adjusted in real-time.

Prof. Kuniaki Dohda

  • Professor of Department of Mechanical Engineering, Northwestern University, USA
  • President of the International Research Group of Tribology in Manufacturing (IRGTM)
  • Fellow of American Society of Mechanical Engineers
  • Fellow of Japan Society of Mechanical Engineers
  • Fellow of Japan Society of Technology of Plasticity

Keynote Title: "Tribology in Micro-Forming Processes"

Demand for micro-manufacturing is increasing as micro machine such as communication devices and medical devices become mall. When using the conventional mechanical manufacturing technology, micro-manufacturing has problems in term of accuracy and reproducibility due to the influence of size effect. The main reason for them is that the manufacturing relative accuracy (tolerance / part size) decreases as the scale downsizing. The relative accuracy in micro processing is comparable to that of the macro processing. This technology can be realized by combining of three technologies, control of materials microstructure, control of the tribological behavior, and improvement of precise manufacturing.

Academic goal of the micro-manufacturing is establishment of the design methods including forming limit prediction. Designing in micro-manufacturing is quite different from the conventional macro-fabrication, and it is necessary to design micro texture of materials and to control the interface of the workpiece.

In the case that some factors do not become small as the product size become small, size effects appear in plastic deformation and frictional behavior in forming processes. In short, size effects appear because of inability downsizing the crystal structure of the workpiece relatively. Discontinuity of crystal plasticity appear in the shape of workpiece. When the size and orientation of the crystal in each workpiece are different, a variation of the shape will appear after deformation. While, size effects on frictional behavior occur when it is difficult to fabricate to generate different surface roughness of both of the tools and workpieces by conventional machining to downsize them.

In this Keynote Speech, at first, the difference between macro- and micro-forming is explained, subsequently, the features of micro-forming and the current understanding of tribological phenomena in micro-forming and the present state of research. Finally one of the future trends of research for tribology in micro-forming is to be described.

Industrial Presentation Speakers

Mr. Masato Otake

Mr. Masato Otake

  • Chief Researcher of Central Research Laboratories, Nihon Parkerizing Co., LTD.
  • Researcher, Product Development of Lubricant for Cold Forming, Nihon Parkerizing Co., LTD.
  • Researcher, Tribology in Metal Forming Process, Nihon Parkerizing Co., LTD.

Presentation Title: "New Trends in Lubricants for Cold Forging"

Phosphating and soap process has been applied to cold forging since World WarⅡ. Now, this process has become indispensable to heavy extrusion process. However, this process has some environmental problems. We have developed a new lubricant system called “Parker Ultimate Lubrication System (PULS)” for cold forging. It is a water based, non-reactive, dry-in-place and single in-line process that makes lubrication coating without generating any waste sludge and water. The coating shows excellent performance for heavy extrusion. The PULS leads to significant total cost reduction.

Mr. Nutthawut Rungsimutuchat

Mr. Nutthawut Rungsimutuchat

  • Researcher, Product development of industrial lubricants, PTT Public Company Limited
  • Engineer, Technical services of aviation and marine lubricants, PTT Public Company Limited
  • Area Manager, Sale of marine lubricants, PTT Public Company Limited
  • Engineer, Technical services of industrial lubricants and specialty products, PTT Public Company Limited

Presentation Title: "Impacts of Bio-Fluid Global Trends to Thailand Market"

For an era, global trends consumption of bio-based hydraulic fluid has been increased subject to government regulation and hydraulic OEMs standard. The requirements of Bio-Based Fluid has been well selected for regulating criteria and properties in order that lubricant would not be harmful to the environment, which is related to ingredients of particular lubricant to function and perform as degrading in an environment, e.g. soil and sea. In addition, it still has to balance between key performances of hydraulic together with degradable properties in order to replace mineral base hydraulic in the future. For this big change, it would be signal to Thailand entrepreneur to prepare for upcoming trends.

Dr. Eric Gard

  • President and CEO of Crescient (InS France, InS Thai, EMTT, Crealins)
  • Chargé de Conference of Ecole Nationale des Pétroles et Moteurs
  • Operational Director of Condat Group
  • Operational Director of Orapi Group
  • Operational Director of Acheson

Presentation Title: "Contribution of hot multifriction tribological tests on the understanding of wear and friction behaviour in hot forging application"

Technologies and simulation models allows now helping in working on the improvement of forging tool wear and supported thermal and tribological constraint, with some possible deduction on metal movement prediction, and optimizing. However current simulations does not includes the fundamental principle of ternary diagram Pressure/Velocity/temperature. The presentation will show the possibilities offered by specialized studies through hot a multifriction tribometer in various situation of forging and issues. The purpose is to make listeners understanding the benefit of such tool and related possibilities for improving their process and productivity in several lubricant, alloys, forging situation examples. The conclusion of this presentation will indicate the various concrete application of such studies in different forging situations.

Dr. Yoshikatsu Nagasawa

  • Technical Consultant of Analytical Chemistry
  • Part-Time Teacher of Ryukoku University
  • Advisor, Executive Director, Chief General Manager of Research Division of Toray Research Center Inc.

Presentation Title: "Role of Latest Analytical Chemistry in Company"

Analytical chemistry was said to be the study of the separation, identification, and quantification of the chemical components of natural and artificial materials. The high reliability “Precision” and “Accuracy” of various analytical instruments, which were developed in the 20th century, were pursued by many analytical chemists. By the effort of these people, the analytical instruments were spread all over the world. Then the study of the trace level quantification enabled the detection of the ppb level of mercury, Dioxin and semiconductor impurities. In the 21st century, the remarkable progress of a digitization technology and the technological advance of personal computer evolve an analytical instrument to the tool supporting the development of advanced materials. The engineer, who does not specialize in analytical chemistry, has been able to use high-performance analytical instruments in a company. These instruments have capabilities to detect one atom, and to grasp a few nm size thin layer structure.

Dr. Wanxin Sun

Dr. Wanxin Sun

  • Applications Manager-APAC, Veeco Instruments
  • Application Manager-APAC, Bruker Nano-Surface
  • Research Scientist, Institue of Bioengineering and Nanotechnology

Presentation Title: "Development of High Efficient Universal Tribology Testing Platform"

Friction and wear are universal research topics in almost every branch of science and engineering, ranging from daily life related research and development activities such as smart phones, cars, and trains, to outer space researches. To enhance energy utilizing efficiency, reducing friction and wear is a continuous effort in different engineering aspects including re-designing engineering parts, coating with nanomaterials and developing advanced lubricants to minimize energy consumption. During these processes, extensive tribology tests are required and need to mimic the real situation, in terms of load, speed and lubrication. The recent advances in tribology demands higher accuracy in force and motion control. At the same time, many different tribology properties need to be studied on the same object. However, existing tribology testing tools are usually designed for a specific experiment, for example four-ball testing for lubricant. Tribologists thus need multiple testing tools to assess different aspects of an object under scrutiny. Generally, it is a challenge to conduct multiple tests using multiple tools on the same location or same material, making it difficult to correlate different properties, which is critical in understanding the mechanism behind. Therefore, a high efficient versatile tribology testing platform is highly valued.

In this article, we report the development of a versatile testing platform, which can cover most of the standard tests, ranging from lubricant, coating reliability, friction and wear on mechanical parts, tribology test under controlled environment, such as temperature, gas environment, electrochemical environment. A new force sensing technique has also been developed to significantly reduce the noise level and greatly enhance the sensitivity. With the new force sensor, the platform’s capability is extended beyond the traditional tribology test, such as sophisticated scratch test to measure thin film adhesion energy, indentation for micro/nano hardness test. Multiple tests can be implemented on the same platform, enabling multi-dimensional tribology properties obtained on the same sample. In addition, the platform caters sophisticated or user tailored tests via high level language scripting, as well as empowering users to achieve multiple-step tests automatically. As a result, the test efficiency is greatly improved compared with traditional tribology testers.

A series of experiments have been carried on the new versatile platform. In this article, we will report several application case studies, including Stribeck curve analysis on green lubricants, adhesion energy analysis of different coatings, micro/hardness on device surface, tribology test on bearing. A few examples under controlled environment will also be discussed.

Co-Chairs

Assoc.Prof. Varunee Premanond

King Mongkut’s University of Technology Thonburi (KMUTT)

varunee.pre@kmutt.ac.th

Asst.Prof. Numpon Mahayotsanun

Khon Kaen University (KKU)

numpon@kku.ac.th