A universal thermoelectric process-driven adhesion compensation system

Adhesion wear during blanking of aluminium is a well-known and industrially relevant problem, as adhesion formation is influenced by process-inherent thermoelectric currents arising from the Seebeck effect. Previous studies have shown that externally applied countercurrents can reduce adhesion by suppressing these thermoelectric currents. However, their application has been limited to time constant countercurrents whose magnitudes had to be calibrated through numerous experimental trials. In this work, a universally integratable compensation system enabling time-resolved countercurrents is introduced. Different process-driven countercurrent strategies are systematically compared, allowing the most effective strategy to be isolated. Based on this strategy, a linear calculation formula for the required countercurrent magnitude is established. Throughout the study, non-lubricated blanking of AA5754 (2.5 mm and 4.0 mm) was investigated. The calculation formula is experimentally validated by varying material thickness, cutting speed, and punch material. The proposed approach achieves a reduction of the mean adhesion height on the punch by 28% to 67%, while reducing the experimental effort by more than 85%.