INSTRUMENTATION • ELECTRONICS
Handheld instant friction
testers can be used on angled or contoured surfaces to optimise the metal forming process
the task. Friction testing may be necessary on angled or contoured surfaces, and in multiple locations. Most traditional testing equipment, however, is not portable, requires removing a sample to the lab area, and is limited to analysing horizontal surfaces.
SIMPLIFIED FRICTION TESTING
Portable, handheld instant friction testers can be used on angled or contoured surfaces to optimise the metal forming process, protect equipment and improve product quality
M
etal forming is a fabrication process in which manufacturers create a range of structural parts and components from metal sheets or tubing, bending or deforming a piece of metal into its desired shape without any removal. T e process modifi es metal or a workpiece by the application of mechanical forces and often heat. Since there is contact between the forming tool and the metal being deformed, friction occurs in almost every part of the process. Insuffi cient control of friction can
cause excessive heat, galling and seized parts, as well as worn edges and tools, resulting in defects. For this reason, manufacturers typically lubricate contact surfaces to facilitate the process and prevent defi ciencies.
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As properly controlling friction impacts the success or failure of the metal forming process, friction testing is a vital part of monitoring and maintaining the proper conditions to produce quality products. “In metal forming, anyone who’s had
problems with lubrication, surface fi nish or other friction-related issues understands that friction testers are a key piece of equipment. Unless they accurately test, they won’t know if they have a sporadic or recurring problem, which can lead to costly, out-of-spec products, until corrected,” says John Bogart, managing director of Kett, a manufacturer of a full range of static and dynamic friction testers as well as surface property analysers for various industries. T e challenge is that traditional friction testing equipment is not always up to
As a solution, portable, handheld friction testers have been developed that enable fast, lab quality, non-destructive testing by essentially anyone without specialised training. With this capability, in situ testing of various materials and surfaces can be completed in seconds, even at an angle, upside down or with contours. On the production fl oor, this capability enables quick adjustments of lubrication and other factors to optimise metal forming, product quality and machine longevity. In the fi eld, it can also be used as a QA check anywhere that friction testing is necessary.
TRADITIONAL FRICTION TESTING CHALLENGES Traditionally, friction testing has been relegated to occasional spot checking in labs using conventional incline methods. T is required destructive testing in which a portion of metal was cut from a sample, mounted on a fl at plane of a second metal, with careful measurement of the inclination angle required for relative movement to start. T e time-consuming process also required considerable technical expertise. To reduce the friction during metal forming, lubricants are often used but this can further complicate testing. Friction is frequently tested to evaluate the eff ect of various lubricant properties and control the results on the forming process. However, the application of lubricants essentially “changes the equation” of how much friction and force is applied in certain areas and processes of metal forming, so friction must be accurately and reliably measured to maintain consistent quality.
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