Interactive Friction Modelling and Digitally Enhanced Evaluation of Lubricant Performance During Aluminium Hot Stamping

Conventional lubricant testing methods focus on lab-scale constant contact conditions, which cannot represent the scenarios in actual hot-stamping processes. In recent studies, the concept of the ‘digital characteristics (DC)’ of metal forming has been proposed by unveiling the intrinsic nature of the specific forming, which presents a timely solution to address this challenge. In this work, the transient behaviours of three dedicated lubricants during the hot stamping of AA6111 material were investigated considering the effects of various contact conditions using an advanced friction testing system, and the interactive friction modelling was established accordingly. The lubricant limit diagram (LLD) of each lubricant was then generated to quantitatively evaluate the lubricant performance following the complex tool–workpiece interactions based on the tribological DCs, and a detailed investigation on the lubricant failure regions was conducted based on the interactive friction modelling. Finally, the industrial application index (IAI) was proposed and defined as a comprehensive evaluation of lubricant applications in the industry, and the most suitable lubricant was identified among the three candidates for mass production.