Experimental and Simulative Investigations of Tribology in Sheet-Bulk Metal Forming

Beyer F, Blum H, Kumor D, Rademacher A, Willner K, Schneider T (2015)

Publication Language: English

Publication Type: Journal article

Publication year: 2015

Journal

Key Engineering Materials Trans Tech Publications

Publisher: Trans Tech Publications

Book Volume: 639

Pages Range: 283-290

URI: http://www.scientific.net/KEM.639.283

DOI: 10.4028/www.scientific.net/KEM.639.283

Abstract

Friction has a considerable influence in metal forming both in economic and technical terms. This is especially true for sheet-bulk metal forming (SBMF). The contact pressure that occurs here can be low making Coulomb’s friction law advisable, but also very high so that Tresca’s friction law is preferable. By means of an elasto-plastic half-space model rough surfaces have been investigated, which are deformed in such contact states. The elasto-plastic half-space model has been verified and calibrated experimentally. The result is the  development of a constitutive friction law, which can reproduce the frictional interactions for both low and high contact pressures. In addition, the law gives conclusion regarding plastic smoothening of rough surfaces. The law is implemented in the framework of the finite element method (FEM). However, compared to usual friction relations the tribological interplay presented here comes with the disadvantage of rising numerical effort. In order to minimise this drawback, a model adaptive finite element simulation is performed additionally. In this approach, contact regions are identified, where a conventional friction law is applicable, where the newly developed constitutive friction law should be used, or where frictional effects are negligible. The corresponding goal-oriented indicators are derived based on the “dual-weighted-residual” (DWR) method taking into account both the model and the discretisation error. This leads to an efficient simulation that applies the necessary friction law in dependence of contact complexity.

Authors with CRIS profile

Florian Beyer Sonderforschungsbereich/Transregio 73 Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen - Blechmassivumformung Kai Willner Professur für Strukturmechanik Thomas Schneider Sonderforschungsbereich/Transregio 73 Umformtechnische Herstellung von komplexen Funktionsbauteilen mit Nebenformelementen aus Feinblechen - Blechmassivumformung

Additional Organisation(s)

Sonderforschungsbereich/Transregio 73, C1: Konstitutives Reibgesetz zur Beschreibung und Optimierung von Tailored Surfaces Sonderforschungsbereich/Transregio 73, A1: Verfahrenskombination zur umformtechnischen Herstellung von verzahnten, dünnwandigen Funktionselementen aus prozessoptimierten Blechhalbzeugen

Related research project(s)

Constitutive friction law for the description and optimization of tailored surfaces TRR 73: Manufacturing of complex functional components with variants by using a new sheet metal forming process - Sheet-Bulk Metal Forming Jan. 1, 2009 - March 31, 2021

Involved external institutions

Technische Universität Dortmund DE Germany (DE)

How to cite

APA:

Beyer, F., Blum, H., Kumor, D., Rademacher, A., Willner, K., & Schneider, T. (2015). Experimental and Simulative Investigations of Tribology in Sheet-Bulk Metal Forming. Key Engineering Materials, 639, 283-290. https://doi.org/10.4028/www.scientific.net/KEM.639.283

MLA:

Beyer, Florian, et al. "Experimental and Simulative Investigations of Tribology in Sheet-Bulk Metal Forming." Key Engineering Materials 639 (2015): 283-290.

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