Advanced friction simulation of standardized friction tests: a numerical and experimental demonstrator

Hol, J.; Wiebenga, J.H.; Hörning, M.; Dietrich, Florian; Dane, Chiel

doi:10.1088/1742-6596/734/3/032092

Cited by 8 publications

(6 citation statements)

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Section: State Of the Art Of Friction Measurement In Cold Bulk Metal supporting

confidence: 73%

“…Barcelonna et al have, for example, shown that using the ring compression test (RCT) and the double cup extrusion test (DCET) for the same tribological system yields friction factors ranging from = 0.04 to = 0.2 [5]. The friction factor m here describes a proportional factor, linking the shear stress τr and the yield stress in shear k as follows: τr =m × k. Similar findings for sheet metal forming friction tests have been presented by Hol et al [6]. Groche et al have recently presented a systematic evaluation of six established tribometers: the ring compression test with boss (RCT-B), the combined forward rod backward can extrusion test (CFRBCET), the backwards cup extrusion test (BCET), the backward can extrusion with simultaneous rotation test (BCERT), the upsetting sliding test (UST), and the sliding compression test (SCT).…”

Section: State Of the Art Of Friction Measurement In Cold Bulk Metal supporting

confidence: 66%

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Friction Measurement under Consideration of Contact Conditions and Type of Lubricant in Bulk Metal Forming

Krämer¹,

Groche²

2019

Lubricants

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The tribological system plays a critical part in designing robust and efficient cold forging operations. The appropriate selection of lubrication allows to forge defect-free workpieces with high dimensional precision and desired surface finish while ensuring that no defects, such as cracks or seams, occur. Additionally, friction and wear are highly affected by the choice of tribological system, which in turn influence the cost-effectiveness of the forging operation by preventing premature tool failure. Next to the employed tool coating and work piece material, the lubrication system and work piece surface topography are the main factors influencing the aforementioned constraints when designing efficient forging operations. In order to choose the appropriate tribological system before implementing it within an industrial forging operation, tribometers are used to characterize the performance of the tribological system. In this paper, the necessity to account for not only the tribological loads when designing these tribometer tests as is typical for existing methodologies, but also for process and lubricant specific properties will be highlighted. With the help of the tribometer sliding compression test, it will be shown that using liquid lubricants necessitates the need to account for the escape of lubricant, while this is not true for solid lubricants. The escape of lubricant from the contact zone is governed by lubricant properties as well as the contact kinematics and may lead to significantly different results regarding friction and wear. In order to account for this escape, the tribometer test must be specifically designed to reproduce the contact kinematics of the investigated industrial forging operation.

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Section: State Of the Art Of Friction Measurement In Cold Bulk Metal supporting

confidence: 73%

Section: State Of the Art Of Friction Measurement In Cold Bulk Metal supporting

confidence: 66%

Friction Measurement under Consideration of Contact Conditions and Type of Lubricant in Bulk Metal Forming

Krämer¹,

Groche²

2019

Lubricants

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“…In a further step, the mutual influence between the contact partners during relative movement is simulated and as a result the COF can be calculated. However, it still needs several input variables such as a three-dimensional tool and blank surface measurements, determination of the material properties of the tool and a blank in the surface near the area, analyses of the lubricant viscosity and friction tests for calibration [5]. On the one hand, the COF can be calculated load-dependently without any additional financial expenditure.…”

Section: Introductionmentioning

confidence: 99%

“…dimensional tool and blank surface measurements, determination of the material properties of the tool and a blank in the surface near the area, analyses of the lubricant viscosity and friction tests for calibration [5]. On the one hand, the COF can be calculated load-dependently without any additional financial expenditure.…”

Section: Introductionmentioning

confidence: 99%

Influence of Test Stand and Contact Size Sensitivity on the Friction Coefficient in Sheet Metal Forming

2018

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The precise knowledge of frictional behavior is highly relevant for accurate modelling in sheet metal forming simulations. This allows e.g., the precise prediction of restraining forces which, in turn, determines an optimal draw bead strategy and blank-texture-development for automotive components. As a result, tryout loops can be avoided and thus production costs can be reduced. Nevertheless, the benefit of this detailed friction description is often ignored by the use of a constant friction coefficient. Finding a practical solution has motivated numerous research projects in recent decades. In this context, many efforts have been made to develop test stands to gain a better understanding of friction and to determine load-dependent friction coefficients for simulations. However, different test stands for friction investigation show a big quantitative difference in friction value which makes the direct use of the values in finite element simulation questionable. Therefore, the focus of this paper is to compare two different common strip drawing tests and detect the sources of deviation. In particular, the influence of the contact area between tool and blank is investigated. The results indicate that while the effect of the different test stands is negligible, a high dependency of the friction coefficient on the contact area was shown. This phenomenon is caused by macroscopic lubricant distribution over the contact area, which varies according to the size of the tools. The results show a potential field of research in categorizing different friction test stands and resolving the issue of quantitative non-comparable coefficients of friction.

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“…This demonstrates its effectiveness in AADD variable COF simulation. Since 2016, there is an extensive collaboration on friction modelling between Volvo cars [135][136][137][138][139][140][141][142], Mercedes-Benz cars [133,143], Ford cars [144], Renault cars [145], Opel cars [5,146], and TriboForm engineering. The involved automotive panels are Volvo's inner door, front door ringframe, A-pillar reinforcement panel, and fender, Mercedes-Benz's door-outer and front fender, Ford's hood inner panel, Renault's trunk lid inner part, and Opel's spare wheel well.…”

Section: Variable Cof Simulationmentioning

confidence: 99%

Advances in friction of aluminium alloy deep drawing

Gao

Zhao

et al. 2023

Friction

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Broad use of lightweight aluminium alloy parts in automobile manufacturing, aerospace, electronic communication, and rail transit is mainly formed through deep drawing process. Deep drawing friction is a key boundary condition for controlling the forming quality of aluminium alloy parts. However, due to the oxidation and adhesion tendency of aluminium alloys, the tribological situations of aluminium alloy deep drawing (AADD) system is more complicated than those of traditional deep drawing of steel sheets. Therefore, the study of AADD friction is essential for manufacturing high-performance aluminium alloy parts. Herein, aiming to provide a valuable reference for researchers in related fields, a comprehensive review of AADD friction is provided, including friction mechanism, influencing factors, friction measurement, friction model, friction simulation, and lubrication-free friction control. Finally, a brief conclusion and several current challenges were discussed.

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Advanced friction simulation of standardized friction tests: a numerical and experimental demonstrator

Cited by 8 publications

References 0 publications

Friction Measurement under Consideration of Contact Conditions and Type of Lubricant in Bulk Metal Forming

Friction Measurement under Consideration of Contact Conditions and Type of Lubricant in Bulk Metal Forming

Influence of Test Stand and Contact Size Sensitivity on the Friction Coefficient in Sheet Metal Forming

Advances in friction of aluminium alloy deep drawing

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