Semi-analytical contact model to determine the flattening behavior of coated sheets under normal load

Shisode, Meghshyam; Hazrati, Javad; Mishra, Tanmaya; Rooij, M.B. de; Boogaard, A.H. van den

doi:10.1016/j.triboint.2020.106182

Cited by 15 publications

(25 citation statements)

References 22 publications

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“…To mimic the sheet metal surface deformation during forming processes, a normal load setup developed by Shisode et al [11] is adopted to perform the combined normal load and sub-surface strain experiments. The setup allows application of a constant nominal pressure on the sheet surface while the material is deformed in uniaxial tension.…”

Section: Combined Normal Load and Sub-surface Strain Experiments 21 mentioning

confidence: 99%

“…Figure 1(a) shows the setup and the sample geometry. Figure 1( [11] for more details on the normal loading of the sample. The longer side of the sapphire notches with rectangular contact area (5 mm × 7 mm) covers full width of the sample (5 mm) at the center.…”

Section: Combined Normal Load and Sub-surface Strain Experiments 21 mentioning

confidence: 99%

“…Zinc coated (GI) and uncoated steel samples which are used in the normal load flattening study [11] are used for the combined normal load and sub-surface strain experiments to investigate the influence of coating thicknesses and surface topography. Table 1 shows the sample details and Fig.…”

Section: Sheet Samples and Test Proceduresmentioning

confidence: 99%

“…Material [11] Coating thickness (μm) [11] Roughness, a S (μm) [11] Mean on the sample ( Fig. 1(a)) where the surface height measurements are performed before and after the experiment to determine the real area of contact using a confocal microscopy.…”

Section: Samplementioning

confidence: 99%

“…The real area of contact for a given loading condition or a combination of loads is generally determined either by dedicated experiments or physics based models. There are numerous models and experimental studies available for normal load flattening for uncoated [4][5][6] and coated sheets [7][8][9][10][11]. In a typical sheet metal forming process, the sheet surface is deformed due to a contact pressure (normal load), sub-surface strain in the sheet metal, and sliding of the tool over the sheet surface.…”

Section: Introductionmentioning

confidence: 99%

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Evolution of real area of contact due to combined normal load and sub-surface straining in sheet metal

et al. 2020

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Understanding asperity flattening is vital for a reliable macro-scale modeling of friction and wear. In sheet metal forming processes, sheet surface asperities are deformed due to contact forces between the tools and the workpiece. In addition, as the sheet metal is strained while retaining the normal load, the asperity deformation increases significantly. Deformation of the asperities determines the real area of contact which influences the friction and wear at the tool-sheet metal contact. The real area of contact between two contacting rough surfaces depends on type of loading, material behavior, and topography of the contacting surfaces. In this study, an experimental setup is developed to investigate the effect of a combined normal load and sub-surface strain on real area of contact. Uncoated and zinc coated steel sheets (GI) with different coating thicknesses, surface topographies, and substrate materials are used in the experimental study. Finite element (FE) analyses are performed on measured surface profiles to further analyze the behavior observed in the experiments and to understand the effect of surface topography, and coating thickness on the evolution of the real area of contact. Finally, an analytical model is presented to determine the real area contact under combined normal load and sub-surface strain. The results show that accounting for combined normal load and sub-surface straining effects is necessary for accurate predictions of the real area of contact.

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Section: Combined Normal Load and Sub-surface Strain Experiments 21 mentioning

confidence: 99%

Section: Combined Normal Load and Sub-surface Strain Experiments 21 mentioning

confidence: 99%

Section: Sheet Samples and Test Proceduresmentioning

confidence: 99%

Section: Samplementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Evolution of real area of contact due to combined normal load and sub-surface straining in sheet metal

et al. 2020

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Surface Texture Design for Sheet Metal Forming Applications

Shisode

Boogaard

Hazrati

2022

The Minerals, Metals &Amp; Materials Series

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Sheet metal surfaces are generally textured to improve tribological performance in deep drawing applications. Variations in coefficient of friction in forming processes is one of the major causes of defective products. The major reasons for an unstable friction condition are the tool wear and inhomogeneity in lubricant amount. Textured surfaces can offer enhanced and stable friction condition. However, there is no clear design guidelines available for texturing sheet metal surfaces for a robust friction condition. Various types of texturing methods are available. In this study, the friction sensitivity of surface texture made by laser-texturing method to variations in tool wear and inhomogeneity in lubricant distribution is investigated. The laser-textured surface parameters such as crater diameter and texture density are chosen within the physically attainable range such that a robust friction behavior during forming process is achieved. A multi-scale friction model is used to determine coefficient of friction for textured surfaces in boundary and mixed lubrication conditions. The friction model in combination with surface generating algorithm is used to optimize individual crater geometry and their spacing. The objective is to determine the surface texture which is least sensitive to the potential variations in the tool roughness and lubricant amount in sheet metal forming applications.

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Multiscale friction model for hot sheet metal forming

et al. 2021

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The accurate description of friction is critical in the finite element (FE) simulation of the sheet metal forming process. Usually, friction is oversimplified through the use of a constant Coulomb friction coefficient. In this study, the application of an existing multiscale friction model is extended to the hot stamping process. The model accounts for the effects of tool and sheet metal surface topography as well as the evolution of contact pressure, temperature, and bulk strain during hot stamping. Normal load flattening and strip drawing experiments are performed to calibrate the model. The results show that the model can relatively well predict friction in strip draw experiments when the tool surface evolution due to wear is incorporated. Finally, the application of the formulated multiscale friction model was demonstrated in the FE simulation of a hot-stamped part.

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Semi-analytical contact model to determine the flattening behavior of coated sheets under normal load

Cited by 15 publications

References 22 publications

Evolution of real area of contact due to combined normal load and sub-surface straining in sheet metal

Evolution of real area of contact due to combined normal load and sub-surface straining in sheet metal

Surface Texture Design for Sheet Metal Forming Applications

Multiscale friction model for hot sheet metal forming

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