The Role of Friction on Metal Forming Processes

Folle, Luís Fernando; Silva, Bruno Caetano dos Santos; Batalha, Gilmar Ferreira; Coelho, Rodrigo Santiago

doi:10.5772/intechopen.101387

Cited by 3 publications

(3 citation statements)

References 25 publications

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“…This analysis depended on the linear relationship of Coulomb's Friction law (15) and the Stribeck diagram for different states of lubrication, as shown in figure 6. (16) As shown in figure 6, there are four lubricant conditions (Dry, Boundary, Mixed, and Hydrodynamic) lubrication, and each type of lubricant condition is used with a special case or special materials. In the case of Aluminium alloys, Boundary lubrication is used with these sheet materials, where this lubricant condition is used with materials that create an oxide layer when touching with air, such as Aluminium.…”

Section: Finite Element Analysismentioning

confidence: 99%

“…In the case of Aluminium alloys, Boundary lubrication is used with these sheet materials, where this lubricant condition is used with materials that create an oxide layer when touching with air, such as Aluminium. (16) In boundary lubrication, the Coefficient of Friction (COF) is between (0,1-0,3). We entered this coefficient range in ABAQUS/EXPLICIT 2020 to determine the suitable coefficient of friction that achieves ISO 12002-2 conditions (Friction should be adjusted so Tearing (crack) occurs at displacement less than 15 % away from the centre of the sample apex of punch diameter used in the test).…”

Section: Finite Element Analysismentioning

confidence: 99%

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Numerical Analysis of the Effect of Coefficient of Friction on the Formability Behaviour of Aluminium AA1060 in the Stretch-Forming Process

Habeeb,

Abed,

Singal

2024

Salud, Ciencia y Tecnología - Serie de Conferencias

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In sheet metal forming processes, the success of the forming process depends on several primary parameters such as the geometry of the tool, Sheet Material Properties, and the Friction in the contact area (tool/workpiece interface). In addition, the process parameters like punch crosshead, deformation temperature, surface roughness of both punch head and sheet blank, lubricant state, and the value of the applied load. Friction in the actual contact area plays a significant effect in obtaining a high-quality part and reducing the production cost. The study provides a new idea to specify the suitable Coefficient of Friction (COF) used when forming Aluminium AA1060, taken according to Coulomb’s Friction Law and Stribeck Diagram for different lubricant states. The methodology of this research is based on the finite element analysis using ABAQUS/CAE 2020 of the Nakajima Formability Test for different Coefficients of Friction (COF) that are taken from Stribeck’s Diagram according to sheet material type, where the suitable Coefficient of Friction (COF) that achieves ISO 12004-2 condition to consider the sheet material successful in the test and valid for use in the manufacturing process. Results show that the Coefficient of Friction (COF) significantly affects the Formability behaviour and specifies the Location of Tearing (crack), where at higher (COF), the Formability of Aluminium AA1060 is decreased. The Tearing (crack) occurs near the circumference of the sample. Consequently, the sample was considered failed in the test and invalid to use in manufacturing processes. At the same time, when (COF) is low, the Formability of the sheet material increases, and tearing occur near the centre of the sample apex, so the sample is considered successful in the test and valid to use in the manufacturing process according to ISO 12004-2.

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Section: Finite Element Analysismentioning

confidence: 99%

Section: Finite Element Analysismentioning

confidence: 99%

Numerical Analysis of the Effect of Coefficient of Friction on the Formability Behaviour of Aluminium AA1060 in the Stretch-Forming Process

Habeeb,

Abed,

Singal

2024

Salud, Ciencia y Tecnología - Serie de Conferencias

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“…Hot forging is a metal shaping technique that applies pressure to a mold to give the workpiece the desired shape [1]. An important factor that leads to workpiece failures is the friction that occurs during the hot forging process [3]. The friction between the die and workpiece in the hot forging process plays a significant role in various aspects.…”

Section: Introductionmentioning

confidence: 99%

A Comparative Study of Lubrication Performance for Bs 080M46 Medium Carbon Steel Using Ring Compression Test and Finite Element Simulation

Poungprasert,

Siripath,

Suranuntchai

2024

KEM

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This study investigates the impact of lubrication on friction factors during the hot ring compression test of BS 080M46 medium carbon steel. Hot forging processes are crucial in industries due to the strength and durability of forged products, but friction-related issues can arise. Four lubrication conditions are focused: dry, oil to black graphite, water to black graphite, and water to colorless graphite. The ring compression test procedure, including sample dimensions and lubrication application, is explained. By employing predictive calibration curves generated through FEM which monitored height and internal diameter changes during compression. The study successfully aligns FEM simulation results with experimental data, thereby enhancing the accuracy of friction factor estimations and visualizing material behavior under various lubrication conditions. Results indicate that lubrication significantly affects friction factors, with oil to black graphite performing the best, yielding a friction factor of 0.15. A comparison between theoretical and experimental friction factors shows varying agreement levels, with water-to-black graphite, and water-to-colorless graphite respectively demonstrating excellent alignment with 0.990% and 0.971%. This study has practical implications for selecting lubricants in industrial applications, potentially enhancing manufacturing processes and product quality.

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Analysis of the friction performance of deep-drawing steel sheets using network models

Najm,

Trzepieciński,

Ibrahim

et al. 2024

Int J Adv Manuf Technol

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This article presents the results of pilot studies on the lubrication of the blankholder zone in sheet metal forming using a pressurised lubricant. The authors invented a method and built a special tribometer for pressure-assisted lubrication. This approach reduces friction in sheet metal forming processes compared to conventional lubrication. Moreover, the artificial neural network approach combined with a force-directed Fruchterman-Reingold graph algorithm and Spearman’s correlation was used for the first time to analyse the relationships between the friction process parameters and the output parameters (the coefficient of friction and the resulting surface roughness of the sheet metal). The experimental tests were conducted utilising strip drawing on four grades of steel sheets known to be outstanding for deep-drawing quality. Different oils, oil pressures and contact pressures were used. Artificial neural network models were used for the first time to determine these relationships in a strip drawing test where every parameter is represented by one node, and all nodes are connected by edges with each other. R Software version 4.2.3 was used to construct the network using the ‘qgraph’ and ‘networktools’ packages. It was found that friction conditions had a highly significant negative correlation with coefficient of friction (COF) and a moderately significant negative correlation with the final surface roughness. However, the initial surface roughness of the as-received sheets had a negative correlation with the COF and a positive one with the resulting surface roughness of the sheet metal. The parameters most related to the COF are the strength coefficient, the ultimate tensile strength and the friction conditions (dry friction or pressurised lubrication). Spearman’s correlation coefficients showed a strong correlation between the kinematic viscosity and the friction conditions.

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The Role of Friction on Metal Forming Processes

Cited by 3 publications

References 25 publications

Numerical Analysis of the Effect of Coefficient of Friction on the Formability Behaviour of Aluminium AA1060 in the Stretch-Forming Process

Numerical Analysis of the Effect of Coefficient of Friction on the Formability Behaviour of Aluminium AA1060 in the Stretch-Forming Process

A Comparative Study of Lubrication Performance for Bs 080M46 Medium Carbon Steel Using Ring Compression Test and Finite Element Simulation

Analysis of the friction performance of deep-drawing steel sheets using network models

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