The Optimum Condition of Manufacturing a Smooth Engineered Surface Using the Internal-Ironing Process

Abstract

Internal-ironing is a newly developed process for making a smooth surface by replicating the tool roughness onto the workpiece. A simple but useful slab analysis is proposed to investigate the influences of operational conditions, such as reduction, die angle, and friction, on the asperity flattening. A new sheet metal forming tribometer is designed to simulate the internal-ironing process. Different lubricants, reductions, and ironing speeds are used in the experiments. The experimental results confirm that the theoretical model is successful in analyzing the smoothing effect. The optimum replication (minimum roughness) lakes place at a moderate reduction of about 30 percent, when the roughness lays (texture lines) of the workpiece are parallel to the ironing direction, well lubricated on the ironing die and unlubricated on the replication side.

KEY WORDS:

• Metalworking
• Forming
• Surface Roughness