A strain-dependent model for the coefficient of friction in the tool-blank interaction in superplastic forming

Sorgente, Donato; Lombardi, Andrea; Coviello, Donato; Scintilla, Leonardo Daniele; Fontana, M.D.

doi:10.1016/j.jmapro.2021.11.050

Cited by 6 publications

(2 citation statements)

References 26 publications

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“…Reference [11] evaluated different surface modification techniques in terms of friction properties. To this end, how the reduction of friction directly affects the stresses received by tools was studied [12]. Brathikan et al [13] related the friction and the blank diameter with the forming force.…”

Section: Introductionmentioning

confidence: 99%

Influence of Friction Coefficient on the Performance of Cold Forming Tools

Barba

Salcedo

Claver

et al. 2023

Metals

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The automotive industry has undergone significant advancements and changes over time, resulting in the use of more complex parts in modern vehicles. As a consequence, the parts used in the manufacturing process are subject to higher stress levels, which reduce their service life. To mitigate this issue, surface treatments can be applied to improve the mechanical properties of the tools. In this study, we examined the impact of surface treatments on reducing tool stress during a cold forming process. The process involved reducing the thickness of a sheet from 6 mm to 2.5 mm, which generated high stresses in the tooling. We used finite element stress calculations to analyze the process and found that by reducing the friction coefficient to 0.1, tool stresses can be reduced by 20%, leading to an increase in tool life. Moreover, the press force and tool wear were also reduced by 18%. To validate the theoretical calculations, we performed field tests in a real manufacturing process.

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Section: Introductionmentioning

confidence: 99%

Influence of Friction Coefficient on the Performance of Cold Forming Tools

Barba

Salcedo

Claver

et al. 2023

Metals

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“…Thus, flexible forming technologies that allow to obtain complex shapes from lightweight alloys are needed. In the recent years, among other flexible forming processes (such as SuperPlastic Forming [3,4], Incremental Forming [5,6] and Hydroforming [7,8]), Magnetorheological Pressure Forming (MRPF) is gaining interest since the thickness and the strain distribution on the formed part can be affected by properly changing the properties of the forming medium [9,10]. In the case of MRPF, the forming medium is a magnetorheological Fluid (MRF).…”

Section: Introductionmentioning

confidence: 99%

Evaluation of the Rheological Behaviour of Magnetorheological Fluids Combining Bulge Tests and Inverse Analysis

Cusanno

Piccininni

Guglielmi

et al. 2022

KEM

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Magnetorheological Fluids (MRFs) are included in the so called “smart materials”: they are suspensions of magnetically responsive particles in a liquid carrier, whose rheological behaviour (e.g., its viscosity) can be changed quickly and reversibly if subjected to a magnetic field. Their application as forming medium in sheet metal forming processes is gaining interests in the recent years since the thickness and the strain distribution on the formed part can be affected by properly changing the properties of the MRF. In order to widely adopt MRFs in such processes, the evaluation of their rheological behaviour according to the applied magnetic field plays a key role. But there are still few works in the literature about the most effective way to characterise the MRFs to be used in sheet metal forming applications.In this work, the rheological behaviour of a MRF is carried out by means of an inverse analysis approach using data from bulge tests performed using an MRF as forming medium. Bulge tests were conducted on sheets having known properties using an equipment with a solenoid to generate the magnetic field, which was specifically designed and manufactured. Pressure rate and magnetic flux density were varied according to a Design of Experiments (DoE) while the strain experienced by the sheet material was acquired by means of a Digital Image Correlation (DIC) system in order to compare it with the numerical one. In particular, the fitting between numerical and experimental data was obtained by changing the MRF’s rheological properties using an inverse analysis technique. The proposed methodology allows to evaluate the MRF behaviour at different levels of both magnetic field and pressure rate, which are determinant for the FE simulation of sheet metal forming processes.

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