Patent ID: 8567226

Claim:
A die for use in a sheet metal forming process, the die comprising: a die material having a surface; and a plurality of depressions formed in the surface of the die material, the plurality of depressions combined having a density such that the plurality of depressions constitutes from about 1% to about 15% of a total area of the surface of the die material while a remainder of the surface is unmodified, and the plurality of depressions being arranged uniformly across the whole surface of the die material, and each of the plurality of depressions having i) a predetermined diameter, and ii) a predetermined depth ranging from about 15 μm to about 25 μm; wherein: the density and the arrangement of the plurality of depressions contribute to a reduction in a coefficient of friction between a sheet metal blank and the die material surface, the reduction of the coefficient of friction being at least 30%; and interaction of a surface of the sheet metal blank with i) the plurality of depressions, and ii) a solid forming lubricant, including particles of an average predetermined size and distribution, disposed on one of the die material surface or the sheet metal blank surface substantially reduces adhesion between the sheet metal blank surface and the die material surface during the sheet metal forming process.