Relationship between friction parameters in a Coulomb–Tresca friction model for bulk metal forming

Zhang, Dawei; Ou, Hengan

doi:10.1016/j.triboint.2015.10.030

Cited by 44 publications

(16 citation statements)

References 18 publications

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“…If the inner diameters of the ring specimens at a 50% reduction in height correspond with Eq. (9), then the value for μ is deemed to be a match with the value for m. The FEM results in the study [38] indicate that when e < 0.005, the inner diameter remains the same with only a slight variation in friction condition due to accuracy of FE model. Thus, e = 0.005 is a suitable value for determining whether the reduction in the inner diameter of the metal ring matches with the correct calibration curve.…”

Section: Friction Conditionsmentioning

confidence: 80%

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Variation of the friction conditions in cold ring compression tests of medium carbon steel

Zhang

Liu

et al. 2019

Friction

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Lubrication and friction conditions vary with deformation during metal forming processes. Significant macro-variations can be observed when a threshold of deformation is reached. This study shows that during the cold compression processing of #45 (AISI 1045) steel rings, the magnitude of friction and surface roughness (R a ) changes significantly upon reaching a 45% reduction in ring height. For example, the R a of compressed ring specimens increased by approximately 55% immediately before and after reaching this threshold, compared to an 18% or 25%variation over a 35%−45% or a 45%−55% reduction in height, respectively. The ring compression test conducted by this study indicates that the Coulomb friction coefficient μ and Tresca friction factor m are 0.105 and 0.22, respectively, when the reduction in height is less than 45%; and 0.11 and 0.24, respectively, when the reduction in height is greater than 45%.

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Section: Friction Conditionsmentioning

confidence: 80%

“…To determine the relationship between Coulomb friction coefficient and Tresca friction factor, Eq. ( 9) was defined as a standard [38]. If the inner diameters of the ring specimens at a 50% reduction in height correspond with Eq.…”

Section: Friction Conditionsmentioning

confidence: 99%

Variation of the friction conditions in cold ring compression tests of medium carbon steel

Zhang

Liu

et al. 2019

Friction

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“…The forming speed is set to 1 mm/s. Moreover, shear friction model was used in the simulation [17]. Ring compression test (RCT) [18] was applied to calibrate the shear factor.…”

Section: Numerical Modelmentioning

confidence: 99%

Reduction of die roll height in duplex gears through a sheet-bulk metal forming method

et al. 2019

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In the existing shearing processes for fabricating parts such as duplex gears, die roll is difficult to avoid. Accordingly, a method based on sheet-bulk metal forming for fabricating a duplex gear with extremely small die roll in one stroke is proposed in the current work. The process could be divided into three stages according to the forming features: upsetting and shearing stage, lateral extrusion stage, and local filling stage. The die roll appeared in the shearing stage, which could be reduced in the subsequent extrusion and local filling stages. To reveal the underground mechanism, material flows under two situations, as a key factor to influence the forming quality, were compared and investigated. The results revealed that by controlling material flow, one could avoid the defects and reduce the die roll.

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“…The Tresca friction model was adopted to describe the friction on the interface between the workpiece and the dies. According to the friction condition used in the numerical simulations for warm or hot forming of aluminum alloy [25,29,34,35] and considering the relationship [36] of friction condition between the Coulomb friction model and the Tresca friction model, the friction factor m = 0.2 was adopted in this study. The velocity of the punch was 0.5 mm/s, which pushed the upper die down.…”

Section: Through-process Finite Element Modeling For Local Heatingmentioning

confidence: 99%

Through-Process Finite Element Modeling for Warm Flanging Process of Large-Diameter Aluminum Alloy Shell of Gas Insulated (Metal-Enclosed) Switchgear

2019

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The large diameter metal shell component (LDMSC) is an important part of gas insulated (metal-enclosed) switchgear (GIS). The LDMSC with multi branches is filled with gas under certain pressure. The plastic forming process is an efficient approach to manufacturing the high reliability LDMSC. The warm flanging process has been widely used to form LDMSC using aluminum alloy. The forming process is characterized by local heating, and the distribution of temperature is strongly inhomogeneous. Although the wall thickness of the shell is 10 mm to 20 mm, the ratio of outer diameter to thickness is more than 40. These present some difficulties in the flanging process and result in some forming defects. Detailed forming characteristics are hard to obtain by analytical and experimental methods. Thus, the through-process finite element (FE) modeling considering heating, forming, unloading, and cooling is one of the key problems to research the manufacturing process of LDMSC. In this study, the through-process FE modeling of the warm flanging process of LDMSC using aluminum alloy was carried out based on the FORGE. The thermo-mechanical coupled finite element method was adopted in the modeling, and the deformation of the workpiece and the die stress were considered together in the modeling. A full three-dimensional (3D) geometry was modeled due to inhomogeneous distribution in all directions for the temperature field. The simulation data of local flame heating could be transferred seamlessly to the simulations of the deforming process, the unloading process, and the cooling process in the through-process FE model. The model was validated by comparison with geometric shapes and forming defects obtained from the experiment. The developed FE model could describe the inhomogeneous temperature field along circumferential, radial, and axial directions for the formed branch as well as the deformation characteristic and the unloading behavior during the warm flanging process. By using the FE model, the forming defects during the flanging process and their controlling characteristics were explored, the evolution of the temperature field through the whole process was studied, and deformation and springback characteristics were analyzed. The results of this study provide a basis for investigating deformation mechanisms, optimizing processes, and determining parameters in the warm flanging process of a large-diameter aluminum alloy shell component.

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Relationship between friction parameters in a Coulomb–Tresca friction model for bulk metal forming

Cited by 44 publications

References 18 publications

Variation of the friction conditions in cold ring compression tests of medium carbon steel

Variation of the friction conditions in cold ring compression tests of medium carbon steel

Reduction of die roll height in duplex gears through a sheet-bulk metal forming method

Through-Process Finite Element Modeling for Warm Flanging Process of Large-Diameter Aluminum Alloy Shell of Gas Insulated (Metal-Enclosed) Switchgear

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