Optimisation of friction surfacing process parameters for a1100 aluminium utilising different derivatives of palm oil based on closed forging test

Nowadays, cold forging is one of the most commonly utilised methods in industrial manufacturing, and most metal-forming lubricants are not ecologically friendly; in some cases, these chemicals may produce large chemical emissions and pose a risk to the community. Bio-oil lubricants have garnered increasing attention as potential alternatives for mineral oil-based lubricants, since they are critical in resolving existing obstacles. This article intends as a case study and demonstrating the usage of different derivatives of palm oil as a bio-lubricant in the closed forging test (CFT). As an outcome of the friction, wear behaviour and deformation, the closed forging test is important in the knowledge of materials and engineering studies. In this test, aluminium (A1100) was utilised to compare the formation of the workpiece using palm oil based and commercial metal-forming oil as a benchmark lubricant. During the forging process, these components' material flow patterns are analysed at intermediate phases of the die stroke level. Using the experimental data, the finite element approach will be used to predict the workpiece friction, effective stress and metal flow. By developing a Coulomb–Tresca friction model, a cold forging test also was used to do studies on the interaction between the Coulomb friction coefficient (CFC) and Tresca shear friction (TSF). From the results, certain types of palm oil-based lubricants perform better than mineral oil-based lubricants in terms of friction coefficient, with palm stearin having the lowest friction coefficient ( m = 0.33/µ = 0.139 ), followed by palm kernel oil and palm mid olein ( m = 0.39/µ = 0.159 ). The palm oil-based lubricant, on the other hand, has generated poor performance in terms of surface texture and surface roughness ( R a ) with a high rate of wear compared to the no sample lubricant and commercial metal-forming oil ( m = 0.42/µ = 0.1675 ).