The selective control of the frictional behavior (tailored friction) in metal forming processes is of high importance with regard to technical and economic aspects. This applies especially for the sheet-bulk-metal forming process. Milling with intentionally invoked regenerative tool vibrations can be applied in order to generate structured surfaces with tailored friction properties on the forming tool. These structures affect the formation of lubrication pockets during the forming process which determine the local frictional properties exceedingly. The full potential of this emerging technology can, however, only be revealed if the heuristic and design-relevant knowledge is acquired and provided to the tool-designer already in the early phases of process development. One thing the tool-designer has to specify is the local frictional behavior on the tool surface. But, however, he does not know which milling parameters lead to the necessary surface structures because in most cases he has no expert knowledge in milling, tribology and forming tools. In this paper data mining is used to determine the frictional behavior based on these parameters. The potential of this method in the described context is revealed by the application on data derived from simulation results, both from milling simulations and contact simulations. The latter are performed by using a Halfspace model for rough surface contact. Both approaches for these simulations, the data mining process and the results are explained to the reader.

Friction has an essential influence on metal forming processes and affects the mould filling strongly. Numerical simulation is widely used because they allow for a efficient product design without the time and cost intensive production of prototype moulds. The quality of the simulation results and thus their reliability is determined by the accuracy of the modelling. For this purpose the applied friction law is of great importance. Characteristic of sheet-bulk metal forming is the coexistence of moderate contact pressures like in sheet metal forming and high contact pressures like in bulk metal forming. The Coulomb friction law is suitable for the sheet metal forming process but it predicts too high friction forces for high contact pressures. On the other hand the Tresca friction law is suitable for bulk metal forming but overestimates the friction for low contact pressures. A smooth transition between the Coulomb and Tresca friction law is described by the Shaw friction law and the Wanheim-Bay friction law. An unresolved problem remains the influence of plastic surface smoothing of structured workpiece surfaces. The tribological properties of the surface are altered by the plastic deformation of the surface roughness. As a consequence the real area of contact and thus the friction are larger in unloading and reloading than in the first loading at the same surface pressure. This plays a role in forming processes with multiple stages, where the surface is smoothed by prior forming operations like for example the forming of tailored blanks. Therefore efforts have been made in the numerical modelling of elasto-plastic surface deformation with a halfspace model. This model allows for the efficient modelling of large rough surfaces because it uses only a surface mesh and not an numerically expensive volume mesh like a Finite-Element model. This halfspace model is calibrated and verified with experimental investigations. A friction law taking into account the plastic surface deformation has been developed based on the halfspace simulations. It distinguishes between first loading, where the current surface pressure is higher than all surface pressures which occurred previously, and unloading or reloading, where the friction is higher because the surface is smoothed plastically in a previous load step, where the surface pressure was higher than currently.

Friction forces are only transferred within the the real area of contact A real , which is usually smaller than the apparent area of contact Ao. The maximum friction stress τ f ric is therefore determined by the shear limit τmax in the area of real contact and the fraction of the real area of contact (τ f ric = τmax). For rough surfaces the size of A real is governed by the plastic deformation of the surface roughness. We present a fully elasto-plastic halfspace contact formulation based on the work of Jacq et al. [1]. Linear elastic-plastic material behavior is modeled based on v.Mises plasticity with isotropic hardening. The algorithm gives the residual stress as well as the full plastic deformation field due to a frictionless normal contact.

Abstract. Friction has a significant influence on the product properties and tool lifetime in metal forming processes. Therefore it frequently limits the possibilities in the product design. A detailed understanding of friction is necessary to overcome this obstacle. Numerical simulations as well as experimental work are required to gain more knowledge on the processes in the contact interface. The multiscale character of surface roughness makes a fine discretisation necessary, which leads to a huge numerical effort. Consequently alternative approaches to a Finite-Element model are of great interest. Halfspace models have shown their potential in elastic calculations and in plastic simulations with a simplified modelling of plastic deformation. In order to advance the modelling of rough contact in metal forming an enhanced plasticity model is applied within the halfspace framework.

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