FINITE ELEMENT MODELING OF STRESS BEHAVIOR IN COLD FORGING PROCESSES UTILIZING PALM KERNEL OIL AS A BIO-LUBRICANT

Abstract

Mineral oils have traditionally been used in most metal-forming lubricants. Vegetable oils, such as palm kernel oil (PKO), may serve as a non-toxic and biodegradable alternative. This study investigates the potential of PKO as a bio-lubricant in metal forming processes using the finite element method. The research focuses on stress-strain characteristics of workpieces lubricated with PKO to evaluate its effectiveness as an environmentally friendly option. The finite element model accurately simulates the mechanical behaviour, highlighting PKO's role in reducing friction, enhancing formability, and minimizing tool wear. A comparison with conventional metal forming oils, using aluminium (AA1100) as a specimen, demonstrates the significant advantages of PKO in promoting process efficiency and sustainability. These findings emphasize the relationship between friction and stress, particularly in low-deformation regions like the dead meal zone.