Scratching aluminium alloys – Modelling and experimental assessment of damage as function of the strain rate

Varga, M.; Leroch, Sabine; Groß, Thomas; Rojacz, H.; Eder, Stefan J.; Grillenberger, Markus; Ripoll, Manel Rodríguez

doi:10.1016/j.wear.2021.203670

Cited by 15 publications

(11 citation statements)

References 22 publications

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“…Since the particles are discrete and interact only via their kernels, the method does not need additional separation formulations to allow for fracture. The GIMP method has been used before to simulate cutting and scratching of metals in good agreement with experiment by Leroch et al (2018), Varga et al (2019), Varga et al (2021. Moreover, in a recent publication, MPM has been applied to grinding processes to investigate the effect of different abrasive orientations, where it was found that there is no material removal at all but pure plowing when a cubic abrasive is oriented with an edge pointing in grinding direction, while the largest chip is formed when the cube is sliding on one of its faces (Eder et al, 2021).…”

Section: Introductionmentioning

confidence: 88%

Towards a multi-abrasive grinding model for the material point method

Leroch

Grützmacher²,

Heckes

et al. 2023

Front. Manuf. Technol.

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An efficient optimization of surface finishing processes can save high amounts of energy and resources. Because of the large occurring deformations, grinding processes are notoriously difficult to model using standard (mesh-based) micro-scale modeling techniques. In this work, we use the meshless material point method to study the influence of abrasive shape, orientation, rake angle, and infeed depth on the grinding result. We discuss the chip morphology, the surface topography, cutting versus plowing mode, the material removal rate, and the chip temperature. A generalization of our model from a straightforward single-abrasive approach to a multiple-abrasive simulation with pseudo-periodical boundary conditions greatly increases the degree of realism and lays the foundation for comparison with real finishing processes. We finally compare our results for multiple abrasives to those obtained for a scaled-down molecular dynamics system and discuss similarities and differences.

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Section: Introductionmentioning

confidence: 88%

Towards a multi-abrasive grinding model for the material point method

Leroch

Grützmacher²,

Heckes

et al. 2023

Front. Manuf. Technol.

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“…In this work, pure aluminum was chosen for investigation, as the material features extensive strain hardening behavior during plastic deformation. Further, it was well characterized in a previous paper of the authors [23], so that the material parameters necessary for the numerical simulation were previously determined. The material is standardized under EN-AW1050A (AA1050) [24], and its chemical composition is given in Table 1.…”

Section: Materials Investigatedmentioning

confidence: 99%

“…The indenter features the same geometry as in the experiments, i.e., Rockwell C shape with 200 µm tip radius. A Coulomb coefficient of friction of 0.1 was set between indenter and sample, as this proved to be representative in previous works [23,28]. For numerical efficiency and to avoid instability issues occurring at long simulation times, only the central 2 mm part of the scratch was simulated at constant depth on an aluminum block the size of 1×3×0.4 mm.…”

Section: Numerical Simulationmentioning

confidence: 99%

“…The speed of the indenter was set to 8 m/s as calculated for the experimental scratch. The JC parameters of the aluminum block are taken from our previous work [23] and given in Table 2. A simulation snapshot of a 20 µm deep scratch is provided in Figure 2 We used high-speed imaging to gain insight into the dynamics of the scratch process.…”

Section: Numerical Simulationmentioning

confidence: 99%

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Fundamental abrasive contact at high speeds: Scratch testing in experiment and simulation

Varga

Cervellón

Leroch

et al. 2023

Wear

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“…Estimation of the real contact area between two contacting solids can be seen as an initial step towards investigating friction and wear of that contact, which are of uttermost interest in various engineering applications [1][2][3][4][5][6][7][8][9][10]. In the context of metalworking, bulk forming operations such as hot rolling of Al alloys are greatly dependent on the contact conditions: the real area of contact partly defines the friction forces that move the workpiece through the roll bite [11], being thus a fundamental aspect of the process.…”

Section: Introductionmentioning

confidence: 99%

Influence of the 6061 Aluminium Alloy Thermo-Viscoplastic Behaviour on the Load-Area Relation of a Contact

et al. 2021

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The contact between solids in metal-forming operations often involves temperature-dependent viscoplasticity of the workpiece. In order to estimate the real contact area in such contexts, both the topography and the deformation behaviour should be taken into account. In this work, a deterministic approach is used to represent asperities in appropriately shaped quadratic surfaces. Such geometries are implemented in indentation finite element simulations, in which the indented material has thermo-viscoplastic properties. By creating a database of simulation data, investigations in terms of contact load and area for the specifically shaped asperities allow for an analysis on the influence of the material properties on the load–area relation of the contact. The temperature and viscoplasticity greatly define how much load is supported by a substrate due to an indenting asperity, but the description of the deformation behaviour at small values of strain and strain rate is also relevant. The pile-up and sink-in regions are very dependent on the thermo-viscoplastic conditions and material model, which consequently affect the real contact area calculation. The interplay between carried load and contact area of a full surface analysis indicates the role that different sized asperities play in the contact under different thermomechanical conditions.

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Scratching aluminium alloys – Modelling and experimental assessment of damage as function of the strain rate

Cited by 15 publications

References 22 publications

Towards a multi-abrasive grinding model for the material point method

Towards a multi-abrasive grinding model for the material point method

Fundamental abrasive contact at high speeds: Scratch testing in experiment and simulation

Influence of the 6061 Aluminium Alloy Thermo-Viscoplastic Behaviour on the Load-Area Relation of a Contact

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