Metal Forming Science and Practice

A State-of-the-Art Volume in Honour of Professor J.A. Schey's 80th Birthday

J.G. Lenard

• Publisher: Elsevier Science
• Year: 2002
• eBook ISBN: 9780080536316
• Topic: Physical Sciences
• Subtopic: Fluid Mechanics

This publication has been written to honour the contribution to science and education made by the Distinguished Professor Emeritus Professor Schey on his eightieth birthday. The contributors to his book are among the countless researchers who have read, studied and learned from Professor Schey's work, which includes books, research monographs, invited papers, keynote papers, scientific journals and conferences. The topics include manufacturing, sheet and bulk metal forming and tribology, amongst others. The topics included in this book include: John Schey and value-added manufacturing; Surface finish and friction in cold-metal rolling; Direct observation of interface for tribology in metal forming; An examination of the coefficient of friction; Studies on micro plasto hydrodynamic lubrication in metal forming; Numerical simulation of sheet metal forming; Geometric and mechanics model of sheet forming; Modelling and optimisation of metal forming processes; The mathematical modelling of hot rolling steel; Identification of rheological and tribological parameters; Oxide behaviour in hot rolling; Friction, lubrication and surface response in wire drawing; and Modelling and control of temper rolling and skin pass rolling.

Chapter 1

Recollections

John Schey: A man who is truly outstanding in his field!

Jean V. Reid IRDI, Midland, Ontario

We affectionately called him Poppa John or Poppa Schey as he patiently taught us the ABC’s of Tribology. However, there was no question of our respect for him. To the outside world, he was still “Professor Schey”, a mentor we strived to be worthy of.

I first met John when I chose him as my project supervisor in the fourth year of my ME program at the University of Waterloo. I had chosen the study of hydrodynamic lubrication in aluminum strip rolling. Little did I know as I met with him that the direction for my career in engineering had been set. From that point on, my course was set to study and work in the Tribology of Manufacturing. I learned high quality experimental techniques for designing experiments, collecting and analyzing data, as well as the art of writing publications and making short technical presentations. I returned to the U of W to study lubrication mechanisms of solid lubricants under John’s guidance for my MASc program. Following my graduation, I worked at General Motors, and at Ontario Hydro Research in the field of tribology. Then, I decided it was once again time to return to the university and study with John; I went back and did my Ph.D investigating adhesion in the unlubricated sliding of stainless steel and copper alloys. It was through his contacts that I moved to Virginia and accepted a job in Reynolds Metals Research. Many years later, it was through John that I once again returned to Canada and am now working at the Industrial Research & Development Institute in Midland, Ontario.

Through the years John has always “been there” to give some friendly advice on Tribology problems or career moves or just say “hello”. Faithfully, by his side, also has been his wife Gitta; she is a pleasure to know as I have seen her as a hard-worker and a serene loving presence supporting his many works while accomplishing much on her own. Their love of music and travel was well known; packing to travel lightly and effortlessly was an art that they had developed.

John set high standards for himself and inspired his students to do the same. He considered an 80-hour work-week to be a standard for his students. He totally believed in learning-by-doing and patiently corrected us when we made mistakes. He did not support paying technicians to do work that we should be able to do for our graduate programs. Thus, I had the challenge of preparing the surface of many of the specimens required for my experimental work. This included many hours of surface grinding with some milling and turning thrown in for variety. Some students chose not to work with John because of his high expectations; for those of us who did, I don’t think we ever regretted our decision. For me personally, it was a joy and an honour to have the tutelage of such a great man.

He pushed and prodded us into areas even when we lacked the confidence. I recall the time shortly after I’d started my graduate program that he asked me to teach the class on surface roughness. At that time, this was a subject that I knew virtually nothing about. I did some background work and taught the class with shaking knees and amazingly enough made it through the lecture period. This is an area that I ended up working in years later, and it all started with a request from John to do something I didn’t think I could do.

I also vividly recall taking my thesis to him for ‘editing’. He told me that “I could write” so I should go ahead and do it. The message (although so gently given) was that I should not be giving him less than my best and expect him to “fix it” for me. He never spoon-fed his students but patiently pushed us to develop our abilities and think about what we were doing. He quickly taught us the error in mindlessly generating data without considering its relevance.

John was a welcome speaker at many technical meetings … his lectures were never boring. He could temper the theory with colourful stories from industry to bring the whole picture to life; instead of just words, we were given the animation to go with it.

It is hard to express the honour of having had the opportunity and blessing of being mentored by John Schey. I was struck by his humility; he always gave us credit for work that he had guided us through. He encouraged us to write and present papers, and accept all challenges that we met in life. Any contribution that students made to work he was involved in was gratefully acknowledged. He was never too busy to appreciate any small thing that we did as students. He was always there with an encouraging word if we were dealing with any problems, whether of a technical or personal nature.

All in all, my life as a student, researcher and engineer has been shaped and motivated by John.

John Schey - A Passion for Tribology in Manufacturing

Gopal Nadkarni

Ispat Inland Inc.

East Chicago, USA

In 1982, I came to the University of Waterloo as a Rotary International Scholar to pursue a short program in Manufacturing Engineering. I had completed my engineering apprenticeship with a cutting tool manufacturing company in India and knew I wanted to study “machinability”. John put me to work on a project determining the effect of lubricant viscosity on machinability; he even funded me when my scholarship ran out. Now, nearly twenty years later, my primary recollections of John are tinged with feelings of affection for John the humanist rather than the awe I felt at his towering intellectual accomplishments. John worked 16-hour days at his passion - Tribology & Manufacturing. He was exacting, demanding and impatient with sloppy work and gifted with an unusual sense of “practicality in research”. He patiently guided his students with compassion and firmness, and used unique methods to educate and inspire them.

I remember well the day he asked me “to help him” proofread several chapters of his “Tribology in Metalworking” book. I was proud and eager to help him; I worked hard for several months reading and re-reading the chapters and giving him my suggestions and ideas. Little did I know that I was being educated in John’s inimitable style; I gained an understanding of the system complexities of tribology and an appreciation of his crisp, concise writing style that was always his hallmark. To this day, I have, on my desk, a well-thumbed copy of this book, with John’s scripted note of gratitude for “helping” him!

No mention of John can pass without mentioning Gitta, his dear wife who always has been a bedrock of support for him and who took care of all his graduate students with affection. All in all, a unique and gifted couple who have given to society more than they have taken from it!

Thoughts on John Schey

Greg Dalton

President

TrybSys Inc.

Sudbury, Ontario

I first met Professor John Schey while I was working in the Graphics Lab as a teaching assistant. I was impressed by John’s attention to detail and obvious interest in helping the first year students. The next year I had the privilege of being in his final class of Manufacturing Processes where, with the rest of the class, I came to marvel at his breadth of knowledge in manufacturing. Of all my professors through 7 years of engineering John was best at giving the students a sense of intimacy with the topic … you were there with John seeing the process through his eyes.

When the opportunity came to spend my last work term in John’s tribology lab I jumped at the chance. John seemed to recognize that I was not as interest in the mundane task of data collection but was more interested in finding ways in collecting better data, easier. He encouraged my digressions, and in a matter of weeks he found a skill in me that would become the foundation for my career.

I continued to work with John through my 4^th year project and managed to just qualify for Master’s degree funding from NSERC. As one of John’s last graduate students I profited from his guidance for many hours each week. If pressed I could summarize what I learned in three concepts:

1. all data are meaningful … but it takes careful analysis to make them useful

2. don’t rely just on the numerical data, observe and compare specimens using a “rogues’ gallery”

3. trust in the power of your brain to make sense of data and observations when it has had time to incubate.

Great engineering careers can be measured in many ways: published papers, books, designs and patents. I have colleagues who refer to “Tribology in Metalworking” as the “bible” of metal stamping lubricant development and I know a company president who keeps “Introduction to Manufacturing Processes” on his desk so he can become an instant expert on just about any manufacturing process.

However, I believe that John’s legacy to the metalworking research community is his enthusiasm and integrity in the empirical process. Personally, John has been and continues to be a tremendous teacher, mentor, and friend. I wish John and Gitta all the best on the 80^th birthday of a true renaissance man.

John A. Schey

Matthias Wandel

RIM

Waterloo, Ontario

I first met Dr. Schey when he interviewed me for a summer co-op job in 1990. He was searching around his office saying ‘Now, where did I put my glasses’. I was pretty sure he didn’t mean the pair he had atop his head, but after a bit of looking, I timidly asked if maybe he was looking for the ones on his head. Sure enough, those were the ones! The interview beyond that point went all right, and I got the summer job.

The job was working with the ‘draw bead simulator’ in the Manufacturing Research Lab at the University of Waterloo. There were four students working in the lab that summer. There was one drawbead simulator machine, plus one of a new, more fancy and more automated design that was just being completed. My work revolved around writing software to operate the new machine, as well as some of the debugging of the new machine.

Those machines took a lot of work to operate, with lots of precision measurements and adjustments that had to be made for each new specimen under test. One of us nicknamed Dr. Schey as ‘Dr. Shim’ for his insistence that adjustments be made by adding varying amounts of brass shims, as opposed to having any sort of adjustment screws on the apparatus.

What I came to appreciate about Dr. Schey is that he is very hands-on. He is certainly not afraid of getting his hands dirty. I learned a lot about problems in machinery that was supposed to apply high forces, with high precision. High forces can make even the sturdiest of machines bend visibly, I found. Problems were also found with the load cells, rubber washers, electronics, wiring and everything imaginable. Being just a student, that suited me just fine – debugging the machine was much more fun than operating it. Fortunately, Dr. Schey had much patience both with the machine and with my attitude towards it. When it came to understanding the subtleties of machinery, Dr. Schey could not be beat.

There were various gems of philosophy I picked up from Dr. Schey. One of the best pieces of wisdom I took away from that summer is about adjustments. On one of the many discussions of the topic, Dr. Schey mentioned that industrial dies used to have many many adjustment screws, and it would take skilled people days to set one up. So I asked, how this was different now. He said ‘Nowadays, they just make them accurate’. It’s a piece of wisdom I have often used in software design. Don’t make your software overly adjustable and configurable. Just make it right, so it won’t need adjustment.

Eventually, towards the end of the summer, the new machine did get to a point where its data could be trusted. For subsequent terms, there were other students working with the machines, still using the software I had written for it. Over the course of subsequent years, Dr. Schey produced more machines of similar design, which were sold to various manufacturers for doing drawbead simulations. With the machines went the computer, running the software I had written. Each machine was in some way different from the previous one, requiring some sort of software customisation and more often than not, some debugging of the electronics. Dr. Schey paid me generously for this work, more than I would have dared to ask.

On occasion, changes needed to be made to the software while I was not around. I was quite surprised to find Dr. Schey going into the software and making some changes to it himself. That really impressed me, that a man this ‘old’ should be that at ease with making changes to programs – more at ease with it than most university students. It made me realize that being able to use computers doesn’t have anything to do with age.

A Tribute to Dr. John Schey

Claudio Girolami

Engineering Manager

Oshawa Truck Assembly Centre

GM of Canada

I first ‘met’ Dr. Schey in a telephone call as I was finishing my undergraduate studies at Conco...

Table of contents

• Cover image
• Title page
• Table of Contents
• Copyright page
• Preface
• Chapter 1: Recollections
• Chapter 2: John Schey and Value-Added Manufacturing
• Chapter 3: Introduction – The Scheme of the Book
• Chapter 4: Surface Finish and Friction in Cold Metal Rolling
• Chapter 5: Direct Observation of Interface for Tribology in Metal Forming
• Chapter 6: An Examination of the Coefficient of Friction
• Chapter 7: Studies on Micro Plasto Hydrodynamic Lubrication in Metal Forming
• Chapter 8: Numerical Simulation of Sheet Metal Forming
• Chapter 9: Geometric and Mechanics Models of Sheet Forming Processes
• Chapter 10: Modelling and Optimization of Metal Forming Processes
• Chapter 11: The Mathematical Modelling of Hot Rolling of Steel
• Chapter 12: Identification of Rheological and Tribological Parameters
• Chapter 13: Oxide Behaviour in Hot Rolling
• Chapter 14: Friction, Lubrication and Surface Response in Wire Drawing
• Chapter 15: Modelling and Control of Temper Rolling and Skin Pass Rolling
• Author Index
• Subject Index