Objectif
Manufacturing of packaging parts made in light alloys or ductile materials, or the fabrication of fins for heat exchange coils require during the metal forming processes of the application of lubricants to avoid adhesion between the tool and the material being processed, e.g. aluminium, tin sheet. This adhesion is caused by cold welding processes and can produce unacceptable tool wear and impairment of product quality. In turn, this leads to undesired stops in production and existence of scrapped components which will lower process efficiencies, causing significant losses for manufacturing companies. Therefore, most of the metalworking processes on these materials (e.g. punching, stamping, drawing or cutting) cannot be applied without addition of suitable lubricants. Though this lubrication is necessary, it is undesirable in many manufacturing processes. Most of the intermediate operations in the manufacturing of packaging materials can involve some steps of lacquering or painting for corrosion protection or decorative purposes. Therefore, adequate cleaning of the remnant lubricant is of paramount importance to achieve a good quality product. This operation can be a source of problems, both to guarantee a high quality finished product and from an environmental aspect, due to the disposal of the cleaning agents. Not to mention the influence that the reduction of a binomial lubricant and cleaning agent will have on improving human working conditions in the factory. This proposal aims at increasing the lifetime of forming tools and reducing or eliminating the need for lubrication in packaging materials manufacturing and other forming processes on aluminium material by developing and selectively applying hard and self lubricant coatings on these tools. The coatings to be developed and optimised will be mainly multilayers or compositionally graded functional coatings of DLC, MoS2 and CNX that should be stable and suited for each manufacturing process, providing a combination of high wear resistance and low friction. Surface Technologies proposed within this project are thin film vacuum technologies (Magnetron Sputtering PVD, PECVD and lon Beam Deposition), that have already proved versatile and cost effective on diverse manufacturing tooling. The summarised industrial objectives of this project are: * Improved lifetime and performance of selected forming tools for Al, Sn metal working by 100% by application of wear resistant and low friction coatings. * Reduction or elimination of lubricants and therefore cleaning solvents in forming operations for Al, Sn materials. * Cost reduction (est. cat 15% of total production costs) by elimination of lubricants and disposal of cleaning agents. * Reduced raw material waste by improved efficiency (e.g. a 10% weight saving in a single tin capsule by improved performance of drawing tools can bring about annual savings of 160 Tones of tin only in one SME). * Improved quality of end product. To achieve these objectives the consortium combines the manufacturing expertise of SME companies in the fields of packaging materials made in aluminium or tin for alimentary, pharmaceutical, cosmetic, chemical, etc. uses, with the knowledge from other partners in tooling and coating equipment design and fabrication and, finally, with the experience provided in coating services for tooling and tribology research from R&TD performers. The approach to meet the objectives will need an evaluation of uncoated tools after their industrial performance; the wear resistant and self lubricant coatings will be deposited and characterized on test samples; a selection of optimum coatings will be made according to conditions previously established (e.g. hardness, adherence or wear and friction coefficients); an optimization of deposition conditions will then be made on real tools and, finally, selected tools will be coated for evaluation in industrial conditions. At the end of the project a technical and economic analysis of results will be made by all partners. The research proposed covers in Industrial & Materials Technologies the Area I (Production Technologies), especially by incorporating new efficient and environmentally benign coating and clean (dry) surface technologies into production systems. These will provide increased efficiency, reduce use of lubricants and the need of hazardous cleaning agents. In addition it covers Area 2 (Materials and Technologies for Product Innovation), especially in Materials Engineering with the development of environmentally compatible coating technologies that will improve durability and performance of tooling for European Packaging industries and a wide range of SME manufacturing companies in Europe, improving their competitiveness and helping in making a more rational use of materials.
Champ scientifique (EuroSciVoc)
CORDIS classe les projets avec EuroSciVoc, une taxonomie multilingue des domaines scientifiques, grâce à un processus semi-automatique basé sur des techniques TLN. Voir: Le vocabulaire scientifique européen.
CORDIS classe les projets avec EuroSciVoc, une taxonomie multilingue des domaines scientifiques, grâce à un processus semi-automatique basé sur des techniques TLN. Voir: Le vocabulaire scientifique européen.
- ingénierie et technologie génie mécanique ingénierie de fabrication
- ingénierie et technologie génie mécanique tribologie lubrification
- lettres arts arts visuels
- sciences naturelles sciences chimiques chimie inorganique métal pauvre
- ingénierie et technologie ingénierie des materiaux revêtement et films
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Coordinateur
26006 Logroço
Espagne
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