A combination of several manufacturing process steps in a simultaneous manner allows savings in energy costs, reduced investment and economizing logistical efforts. In particular, this investigation deals with manufacturing and joining of a frictionally engaged shaft-hub-connection by lateral extrusion. One key challenge of such new process management is the prior layout of both optimal friction conditions during manufacturing process on the one hand and highly expected static friction interaction of joined components in order to transmit tangential and axial forces on the other hand. Therefore, cylindrical, thin-walled hubs have been manufactured and joined to shafts. Several parameters describing the tribological system between shaft and hub such as contact surface topographies and lubricant, have been varied within this study. By measuring the radial deformation of the hub, the contact pressure is determined and a normal force applied to the contact surface of shaft and hub is calculated. When separating hub and shaft in a destructive manner, an extensive axial tensile force is applied and measured. According to Coulomb's friction law, specific friction coefficients are calculated depending on manufacturing process parameters as mentioned above.
Friction conditions in sheet metal forming are mainly influenced by the surface topography of blank and tool, its mechanical properties and the properties of the intermediate medium, the lubricant. Aiming towards an analytical determination of friction coefficients for sheet metal forming, such factors should be included in suitable models and be weighted accordingly. In addition to the elastic-plastic deformation of the surface topography of the blank as a result of increasing nominal surface pressure, the influence of the lubricant can be considered using the Reynolds equation. In the present investigation, the flow factors of the elasto-hydrodynamic lubrication and mixed friction, which take into account the effects of surface topography and orientation, were calculated as a function of nominal surface pressure and nominal contact area in terms of plastically deformed surfaces. Asperity deformation is evaluated with a numerical contact model using the flow curve of base metal to calculate local contact forces.
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